Two-part water-based bio-based epoxy with enhanced durability

Abstract

A two-part epoxy formulation that is both water-based and bio-based, exhibiting surprising durability comparable to or exceeding conventional petroleum-based epoxies. The coating composition contains: (A) a water-based epoxy resin; (B) a bio-based hardener; and (C) one or more additives.

Description

[0001] Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0002] TITLE OF THE INVENTION

[0003] Two-Part Water-Based Bio-Based Epoxy with Enhanced Durability

[0004] CROSS-REFERENCE TO RELATED APPLICATIONS

[0005] The present application claims priority to U.S. Provisional Appl. No. 63 / 723,252, filed November 21, 2024 and U.S. Provisional Appl. No. 63 / 735,059, filed December 17, 2024, the entire contents of which are incorporated herein by reference.

[0006] FIELD OF THE INVENTION

[0007] This invention relates to a novel two-part epoxy formulation that is both water-based and bio-based, exhibiting surprising durability comparable to or exceeding conventional petroleum-based epoxies. The coating composition contains: (A) a water-based epoxy resin; (B) a bio-based hardener; and (C) one or more additives.

[0008] DISCUSSION OF THE BACKGROUND

[0009] Epoxy resins are widely used in various industries due to their excellent adhesion, chemical resistance, and mechanical properties. However, conventional epoxy resins are typically derived from petroleum-based materials, raising environmental concerns. Further, traditional epoxy resins are typically derived from petrochemicals and often involve volatile organic compounds (VOCs) and toxic components.

[0010] There is a growing need for sustainable and environmentally friendly alternatives that reduce reliance on fossil fuels and minimize harmful emissions. Bio-based epoxy resins derived from renewable resources have emerged as promising candidates to replace petroleum-based counterparts. However, achieving comparable performance characteristics, particularly in terms of durability and water resistance, has been a challenge. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0011] In view of the foregoing, there remains a critical need in the art to develop safe coating compositions that utilize bio-based epoxy resins but that also have high performance characteristics.

[0012] SUMMARY OF THE INVENTION

[0013] It is an object of the present invention to provide a coating composition comprising:

[0014] (A) a water-based epoxy resin;

[0015] (B) bio-based hardener; and

[0016] (C) one or more additives.

[0017] It is an object of the present invention to provide a kit comprising, the coating composition comprising (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives together with instructions for use thereof.

[0018] It is an object of the present invention to provide a method of making a coating composition, comprising stirring, shaking, or agitating (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives for a time and under conditions sufficient to blend the (A) the water-based epoxy resin, (B) the bio-based hardener, and (C) the one or more additives to substantial homogeneity thus forming the coating composition.

[0019] It is an object of the present invention to provide a method of coating a surface of a material by:

[0020] (1) applying a layer of a coating composition comprising (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives to a surface of a material, wherein the material, and

[0021] (2) allowing the coating composition to cure. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0022] It is an object of the present invention to provide a coated material wherein a surface of a material has a coating of a cured product of a coating composition comprising (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives.

[0023] The above objects highlight certain aspects of the invention. Additional objects, aspects and embodiments of the invention are found in the following detailed description of the invention.

[0024] DETAILED DESCRIPTION OF THE INVENTION

[0025] Unless specifically defined, all technical and scientific terms used herein have the same meaning as commonly understood by a skilled artisan in chemistry (e.g., polyurethane chemistry), coatings, and adhesives.

[0026] All methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, with suitable methods and materials being described herein. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. Further, the materials, methods, and examples are illustrative only and are not intended to be limiting, unless otherwise specified.

[0027] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.

[0028] Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0029] For clarity, the terms “coating” and “coating composition” are used interchangeably herein unless otherwise indicated.

[0030] The present invention provides a coating composition containing:

[0031] (A) a water-based epoxy resin;

[0032] (B) a bio-based hardener; and

[0033] (C) one or more additives.

[0034] In embodiment, the coating composition contains 30 wt% to 75 wt% of component (A) and 10 wt% to 20 wt% of component (B) with the balance being accounted for by component (C).

[0035] Without being bound by any theory, the water-based epoxy resin component provides the primary structural backbone of the cured epoxy. The bio-based hardener component reacts with the resin to initiate the curing process, forming a cross-linked network that imparts strength and durability. The specific type and amount of bio-based hardener can be adjusted to tailor the curing time, mechanical properties, and final characteristics of the epoxy.

[0036] The surprisingly high durability of coating composition of the present invention is attributed to the synergistic interaction between the water-based epoxy resin and the biobased hardener.

[0037] In an embodiment, the bio-based hardener is a nut oil-based hardener. In this embodiment, the nut oil component contributes to enhanced flexibility and impact resistance, while the carefully selected water-based resin ensures effective cross-linking and water resistance.

[0038] In the coating composition described herein, where a wt% is recited it is based on the total weight of the coating composition unless otherwise specified. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0039] (A) Water-Based Epoxy Resin

[0040] In an embodiment, the water-based epoxy resin serves as a primary binder, providing adhesion and film formation. The water-based epoxy resin component provides the primary structural backbone of the cured epoxy.

[0041] In an embodiment, the water-based epoxy resin may include, but is not limited to, epoxidized oils, epoxidized natural rubber, or modified plant-based starches with epoxy functionality.

[0042] In an embodiment, the water-based epoxy resin is an epoxidized oil.

[0043] The epoxidized oil may be derived from a synthetic and / or natural oil.

[0044] In an embodiment, the epoxidized oil can be any suitable epoxidized oil obtained from a sustainable source. The sustainable source can be a plant oil, vegetable oil, tree oil, nut oil (which is different from (A)), or animal oil.

[0045] In an embodiment, the oil is epoxidized using a suitable epoxidation agent, such as a peracid (e.g., peracetic acid) or m-chloroperoxybenzoic acid, to introduce epoxy groups into the triglyceride structure. The epoxidized oil can also be obtained by a simple reaction of a suitable oil with acid and hydrogen peroxide can yield epoxidized oil. A perester may also be used to form an epoxidized oil.

[0046] The epoxidized oil can be a sustainable and / or natural oil (e.g., an oil derived from a plant, vegetable, tree, nut, or animal).

[0047] Epoxidation can be of a subject oil or an oil that has been synthetically or enzymatically modified to incorporate one or more non-conjugated carbon-carbon double bonds.

[0048] Non-limiting examples of oils that can be directly epoxidized include oils that have one or more non-conjugated carbon-carbon double bonds (i.e., an unsaturated fatty acid), two or more non-conjugated carbon-carbon double bonds, three or more non-conjugated carbon- Attorney Docket No. BIOB-12 / 01WO 40787 / 64 carbon double bonds, four or more non-conjugated carbon-carbon double bonds, five or more non-conjugated carbon-carbon double bonds, six or more non-conjugated carbon-carbon double bonds, seven or more non-conjugated carbon-carbon double bonds, eight or more nonconjugated carbon-carbon double bonds, nine or more non-conjugated carbon-carbon double bonds, or ten or more non-conjugated carbon-carbon double bonds. As an upper limit to any of the foregoing ranges, twenty or less non-conjugated carbon-carbon double bonds, fifteen or less non-conjugated carbon-carbon double bonds, twelve or less non-conjugated carbon-carbon double bonds, ten or less non-conjugated carbon-carbon double bonds, nine or less nonconjugated carbon-carbon double bonds, eight or less non-conjugated carbon-carbon double bonds, seven or less non-conjugated carbon-carbon double bonds, six or less non-conjugated carbon-carbon double bonds, five or less non-conjugated carbon-carbon double bonds, four or less non-conjugated carbon-carbon double bonds, three or less non-conjugated carbon-carbon double bonds, or two or less non-conjugated carbon-carbon double bonds are envisioned. As such, envisioned are ranges of the foregoing where a lower limit and an upper limit are selected as illustrated by the following exemplary ranges one to ten non-conjugated carbon-carbon double bonds, one to eight non-conjugated carbon-carbon double bonds, one to six nonconjugated carbon-carbon double bonds, one to four non-conjugated carbon-carbon double bonds, one to three non-conjugated carbon-carbon double bonds, two to ten non-conjugated carbon-carbon double bonds, two to eight non-conjugated carbon-carbon double bonds, two to six non-conjugated carbon-carbon double bonds, two to four non-conjugated carbon-carbon double bonds, two to three non-conjugated carbon-carbon double bonds, three to ten nonconjugated carbon-carbon double bonds, three to eight non-conjugated carbon-carbon double bonds, three to six non-conjugated carbon-carbon double bonds, three to four non-conjugated carbon-carbon double bonds, four to ten non-conjugated carbon-carbon double bonds, four to Attorney Docket No. BIOB-12 / 01WO 40787 / 64 eight non-conjugated carbon-carbon double bonds, and four to six non-conjugated carboncarbon double bonds.

[0049] In an embodiment of the present invention, prior to epoxidation, a subject oil can be subjected to a dehydrogenation (i.e., desaturation) reaction to introduce one or more nonconjugated carbon-carbon double bonds into one more carboxylic chain of a constituent saturated fatty acid. Exemplary reactions of forming an unsaturated fatty acid are direct desaturation utilizing oxygen and NADPH, selective desaturation using a fatty acid desaturase, or anaerobic arrangement. In an embodiment of the present invention, desaturation conditions are controlled to engineer an oil having the foregoing number(s) of non-conjugated carboncarbon double bonds.

[0050] Epoxidation can be of a subject oil or an oil that has been synthetically or enzymatically modified to incorporate one or more non-conjugated carbon-carbon double bonds.

[0051] In an embodiment of the present invention, the oil that can be epoxidized (directly or after dehydrogenation) is almond oil, avocado oil, bay oil, basil oil, bergamot oil, oils derived from biomass, Brazil nut oil, broccoli oil, cade oil, canola oil, caraway seed oil, cashew oil, cashew nutshell liquid, cinnamon leaf oil, citronella java oil, citrus seed oil, cod liver oil, corn oil, cocoa butter, cottonseed oil, cumin oil, cypress oil, fish oil, flaxseed oil, geranium oil, grapefruit oil, hazelnut oil, lavender oil, lemongrass oil, linseed oil, macademia nut oil, mandarine oil, melissa oil, myrtle oil, neem oil, nutmeg oil, oat oil, olive oil, palm oil, palmarosa oil, peanut oil, pecan oil, peppermint oil, pine nut oil, pistachio oil, rapeseed oil, safflower oil, sage oil, sesame oil, soybean oil, spearmint oil, sunflower oil, high oleic sunflower oil, tea tree oil, thyme oil, triolein, vegetable oil, Vernonia oil, vetiver Haiti oil, walnut oil, wormwood oil, ylang ylang oil or any combination of two or more of the foregoing oils. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0052] The degree of epoxidation of the foregoing oil may be partial (at least 10%, at least

[0053] 20%, at least 25%, at least 30%, at least 33%, at least 40%, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 90%, or at least 95%) or complete (100%) of the nonconjugated carbon-carbon double bonds. The foregoing percentages are understood to be average degrees of epoxidation across all epoxidized oils present in the adhesive composition. For example, in an embodiment of the present invention two or more forms of the same or of different base epoxidized oils can be present in the adhesive composition and, when present, the average degree of epoxidation meets the foregoing ranges.

[0054] Thus, in an embodiment of the present invention, the adhesive composition comprises two or more epoxidized oils of the same (differ by degree of epoxidation) or different (differ by type and / or degree of epoxidation) base oil and, optionally, one or more oil of the same or different type that has not been epoxidized (i.e., 0% epoxidation). Where the epoxidized oil is mixed with an oil of the same or different type that has not been epoxidized, the ratio of the oils is such that the final average degree of epoxidation is at least 10%, at least 20%, at least 25%, at least 30%, at least 33%, at least 40%, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 90%, or at least 95%. In an embodiment of the present invention, the total amount of non-epoxidized oil does not exceed 60% by weight, does not exceed 55%, does not exceed 50%, does not exceed 45%, does not exceed 40%, does not exceed 35%, does not exceed 30%, does not exceed 25%, does not exceed 20%, does not exceed 15%, or does not exceed 10% of the total amount of oil present in the adhesive composition.

[0055] The epoxidized oil of the present invention will have at least one, at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine, at least ten epoxy groups. As an upper limit to any of the foregoing ranges, twenty or less, fifteen or less, twelve or less, ten or less, nine or less, eight or less, seven or less, six or less, five or less, four or less, three or less, or two or less epoxy groups are envisioned. As such, envisioned are Attorney Docket No. BIOB-12 / 01WO 40787 / 64 ranges of the foregoing where a lower limit and an upper limit are selected as illustrated by the following exemplary ranges one to ten, one to eight, one to six, one to four, one to three, two to ten, two to eight, two to six, two to four, two to three, three to ten, three to eight, three to six, three to four, four to ten, four to eight, and four to six epoxy groups. The epoxy groups may be internal or terminal epoxy groups.

[0056] In an embodiment of the present invention, the epoxidized oil has a viscosity of 100 to 1000 cps at 25°C, 200 to 800 cps at 25°C, 300 to 700 cps at 25°C, 400 to 650 cps at 25°C, and 450 to 550 cps at 25°C.

[0057] In an embodiment, the epoxidized oil is epoxidized soybean oil. An exemplary structure of the epoxidized soybean oil is as follows:

[0058] In an embodiment, the water-based epoxy resin is a modified plant-based starch with epoxy functionality. In an embodiment, the starch is, for example, acorn squash starch, arrowroot starch, barley starch, butternut squash starch, cassava starch, corn starch (maize starch), manioc starch, lentil starch, lima bean starch, oat starch, pea starch, potato starch, rice starch, sorghum starch, sweet potato starch, tapioca starch, wheat starch, white potato starch, or mixtures thereof. In an embodiment, the bio-based component is com starch. In an embodiment, the bio-based component is a potato starch.

[0059] In an embodiment, the coating composition contains a total of at least 30 wt%, at least 32.5 wt%, at least 35 wt%, at least 37.5 wt%, at least 40 wt%, at least 42.5 wt%, at least 45 wt%, at least 47.5 wt% or at least 50 wt% of the water-based epoxy resin. The coating composition contains a total of at most 75 wt%, at most 70 wt%, at most 65 wt%, at most 60 Attorney Docket No. BIOB-12 / 01WO 40787 / 64 wt%, at most 55 wt%, at most 50 wt%, at most 47.5 wt%, at most 45 wt%, at most 42.5 wt%, at most 40 wt%, at most 37.5 wt%, or at most 35 wt% of the water-based epoxy resin. In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include 30 wt% to 75 wt%, 35 wt% to 75 wt%, 40 wt% to 75 wt%, 45 wt% to 75 wt%, 50 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 70 wt%, 40 wt% to 70 wt%, 45 wt% to 70 wt%, 50 wt% to 70 wt%, 30 wt% to 65 wt%, 35 wt% to 65 wt%, 40 wt% to 65 wt%, 45 wt% to 65 wt%, 50 wt% to 65 wt%, 30 wt% to 60 wt%, 35 wt% to 60 wt%, 40 wt% to 60 wt%, 45 wt% to 60 wt%, 50 wt% to 60 wt%, 30 wt% to 50 wt%, 35 wt% to 50 wt%, 40 wt% to 50 wt%, 30 wt% to 45 wt%, 30 wt% to 40 wt%, and 35 wt% to 45 wt%.

[0060] The bio-based hardener reacts with the resin to initiate the curing process, forming a cross-linked network that imparts strength and durability.

[0061] In an embodiment, the bio-based hardener component is derived from a modified nut oil. The specific type and amount of nut oil used in the hardener can be adjusted to tailor the curing time, mechanical properties, and final characteristics of the epoxy.

[0062] Suitable nut oils may include, but are not limited to, almond oil, argan oil, avocado oil, Brazil nut oil, cashew oil, cashew nutshell liquid, groundnut oil, hazelnut oil, macademia nut oil, nutmeg oil, pecan oil, pine nut oil, pistachio oil, and walnut oil, which are modified to provide amine functionality for curing the epoxy resin. In an embodiment, the nut oil is cashew nutshell liquid (CNSL), almond oil, walnut oil, or pistachio oil.

[0063] In an embodiment of the present invention, the bio-based hardener is a polyamide including, but not limited to, a dimer acid and tall oil fatty acid. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0064] In an embodiment of the present invention, the bio-based hardener is a furanyl based curing agents which may be derived from polysachharides and sugars. Examples of furanyl based curing agents include 5,5 ’-methylenedifurfurylamine (DFDA), 5,5’- ethylidenedifurfurylamine (CH3-DFDA), bis(furfurylamine)A, furfuryl amine, 2,5- bis(aminomethyl)furan, and difurfurylamine.

[0065] In an embodiment of the present invention, the bio-based hardener is a phenylalkamine (also referred to as phenalkamine) or phenylalkamide (also referred to as phenalkamide). Suitable phenylalkamines may include, but are not limited to, phenalkamine curing agents disclosed in U.S. Pat. No. 6,262,148, the entire contents of which is incorporated herein by reference, phenylethanolamine and phenylpropanol amine. Suitable phenylalkamides may include, but are not limited to, phenyl acetamide and phenyl propionamide.

[0066] Another example of phenalkamine curing agents suitable for use in the present invention are biobased phenalkamine produced using cardanol derived from cashew nut shell liquid and an amine in the Mannich reaction, (e.g., Cardolite products 2009SF, 2002, 3025, and 3070).

[0067] Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0068] Phenalkamines may be particularly advantageous in some embodiments and provide fast cure time, excellent low-temperature curing, excellent flexibility, excellent water, corrosion, and chemical resistance properties, and long pot lives. In an embodiment, the coating composition contains a total of at least 10 wt%, at least

[0069] 11.5 wt%, at least 12 wt%, at least 12.5 wt%, at least 13 wt%, at least 13.5 wt%, at least 14 wt%, at least 14.5 wt%, or at least 15 wt% of the bio-based hardener. The coating composition contains a total of at most 20 wt%, at most 19.5 wt%, at most 19 wt%, at most

[0070] 18.5 wt%, at most 18 wt%, at most 17.5 wt%, at most 17 wt%, at most 16.5 wt%, at most 16 wt%, at most 15.5 wt%, or at most 15 wt% of the bio-based hardener. In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include 10 wt% to 20 wt%, 12 wt% to 20 wt%, 12.5 wt% to 20 wt%, 15 wt% to 20 wt%, 10 wt% to 17.5 wt%, 12 wt% to 17.5wt%, 10 wt% to 15 wt%, 12 wt% to 15 wt%, and 12.5 wt% to 15 wt%. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0071] Additives

[0072] In an embodiment of the present invention, the two-part epoxy formulation comprising components (A) and (B), may further contain one or more additives to account for the remaining balance of the composition. In an embodiment, component (C) (i.e., one or more additives) are added to component (B). In an embodiment, component (C) (i.e., one or more additives) are added to component (A). In an embodiment, component (C) (i.e., one or more additives) are added to component (A) and component (B).

[0073] Examples of such additives include:

[0074] • Solvent: To adjust viscosity and facilitate water-based dispersion.

[0075] • Fillers: To enhance mechanical properties and further increase the bio-content.

[0076] • Plasticizers: To improve flexibility and processability.

[0077] • Stabilizers: To enhance shelf life and prevent premature curing.

[0078] • One or more other additives: To affect the properties of the composition based on the intended use.

[0079] (C-l) Solvent

[0080] In an embodiment, the coating composition comprises one or more solvents. Inclusion of a solvent may facilitate adjustment of the viscosity and facilitate water-based dispersion.

[0081] The solvent includes, but is not limited to, alcohols such as ethanol or methanol, water, chloroform, dichloromethane, dimethyl sulfoxide, and dimethyl formamide.

[0082] The coating composition may contain a total of at least 2.5 wt%, at least 5 wt%, at least 7.5 wt%, at least 10 wt%, at least 12.5 wt%, at least 15 wt%, at least 17.5 wt%, or at least 20 wt% of a solvent. The coating composition contains a total of at most 35 wt%, at most 30 wt%, at most 25 wt%, at most 20 wt%, or at most 15 wt% of a solvent. In an Attorney Docket No. BIOB-12 / 01WO 40787 / 64 embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above.

[0083] In an embodiment, the solvent is water-based (i.e., is contained in water as a solvent). In an embodiment, the solvent is water. In an embodiment, the solvent has low VOC content or is free from (i.e., has zero) VOCs. In and embodiment, the solvent is free from VOCs. In an embodiment, the coating composition is free from organic solvents.

[0084] (C-2) Fillers

[0085] In an embodiment, the coating composition contains one or more fillers. Inclusion of fillers may enhance mechanical properties and / or further increase the bio-based components content.

[0086] In an embodiment, the filler is selected from ground or precipitated calcium carbonate, optionally coated with fatty acid (e.g., stearates), baryte (heavy spar), talc, quartz flour, quartz sand, silicon carbide, iron mica, dolomite, wollastonite, kaolin, mica (potassium aluminum silicate), molecular sieves, aluminum oxide, zinc oxide, aluminum- doped zinc oxide, aluminum hydroxide, magnesium hydroxide, silica, cement, gypsum, fly ash, carbon black, graphite, metal powders (e.g., as aluminum, copper, iron, zinc, silver or steel), PVC powder or hollow beads or a combination thereof.

[0087] In an embodiment, the filler is a bio-based filler. The use of a bio-based filler is particularly advantageous in some embodiments as it can be used to increase the total biobased components content in the coating composition. Bio-based fillers include lignin powder, pulverized nutshells, fruit stones, wood flour, cork powder, cellulose fibers or a combination thereof. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0088] In an embodiment, the coating composition contains one or more plasticizers. Inclusion of plasticizers may improve flexibility and processability. It is advantageous in some embodiments to utilize a bio-based plasticizer to further increase the bio-based components content.

[0089] Suitable plasticizers include carboxylic acid esters, such as phthalates, especially diisononyl phthalate (DINP), diisodecyl phthalate (DIDP) or di(2-propylheptyl)phthalate (DPHP), hydrogenated phthalates (e.g., hydrogenated diisononyl phthalate or diisononyl cyclohexane- 1,2-dicarboxylate (DINCH)), terephthalates (e.g., bis(2-ethylhexyl) terephthalate or diisononyl terephthalate), hydrogenated terephthalates (e.g., hydrogenated bis(2-ethylhexyl) terephthalate or diisononyl terephthalate), or bis(2-ethylhexyl) cyclohexane- 1,4-dicarboxylate, trimellitates, adipates (e.g., dioctyl adipate), azelates, sebacates, benzoates, glycol ethers, glycol esters, organic phosphoric or sulfonic acid esters, polybutenes, polyisobutenes or plasticizers.

[0090] In an embodiment, the plasticizer is a bio-based plasticizer. The bio-based plasticizer may be derived from natural fats or oils, examples include epoxidized oil (see above) including epoxidized soybean oil or epoxidized linseed oil. The bio-based plasticizer may be a glycerol derivative.

[0091] (C-4) Stabilizers

[0092] In an embodiment, the coating composition contains one or more stabilizers. Inclusion of a stabilizer may enhance shelf life and prevent premature curing.

[0093] In an embodiment, the stabilizer may be a light stabilizer such as UV absorbers and sterically hindered amines (HALS). UV absorbers include substituted benzotriazoles, S- phenyltriazines or oxalanilides. Sterically hindered amines, especially those having a 2, 2, 6, 6- Attorney Docket No. BIOB-12 / 01WO 40787 / 64 tetramethylpiperidyl structure, is described by way of example in A. Valet, Lichtschutzmittel fur Lacke [Light stabilizers for paints], Vincentz Verlag, Hanover, 1996.

[0094] The stabilizer may also include defoaming agents, anti-cratering and / or wetting agents, levelling agents, film-forming auxiliaries, reactive diluents, biocides, solvents or substances for rheology control.

[0095] Stabilizers, for example free-radical scavengers, and other polymerization inhibitors such as sterically hindered phenols stabilize components during storage and are intended to prevent discoloration during curing. Wetting and levelling agents improve surface wetting and / or the levelling of coatings. Examples are fluorosurfactants, silicone surfactants and specific poly acrylates. Rheology-control additives are important in order to control the properties of the two-component system on application and in the levelling phase on the substrate and are disclosed, for example, in WO 9422968, EP0276501, EP0249201 or WO 9712945, which are incorporated herein by reference. It is additionally possible to employ water scavengers, for example triethyl orthoformate, toluenesulfonyl isocyanate, monooxazolidines or molecular sieves, and hydrolysis stabilizers, for example carbodiimides.

[0096] (C-5) Other Additives

[0097] The coating of the present invention may include a further optional additive component. Exemplary additive components include one or more of a promoter, a defoamer, a deaerating agent, a wetting agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a filler, a reinforcement, a chain extender, a corrosion inhibitor, an oil resin (e.g., soy oil resin), a biobased starch, and / or a crosslinker. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0098] Where the additive is a nanotube or a microcarrier, the nanotube and / or microcarrier may contain additives including at least one of titanium dioxide, a pigment, and an antimicrobial agent.

[0099] Exemplary catalysts include catalysts include tertiary amines, Mannich bases formed from secondary amines, nitrogen-containing bases, alkali metal hydroxides, alkali phenolates, alkali metal alcoholates, hexahydrothiazines, and organometallic compounds. An exemplary catalyst is dibutyltin dilaurate, an organotin compound. The catalyst may be added, in amount from 0.001 wt % to 10 wt %, based on the total weight of the system. The catalyst may accelerate the curing time of isocyanate moieties (e.g., in the isocyanate component or in prepolymers) and active hydrogens (e.g., polyols and / or chain extenders) to offer mechanical properties.

[0100] In an embodiment, the crosslinker is a bio-based crosslinker. In an embodiment, the bio-based crosslinker is a propanediol.

[0101] An exemplary antimicrobial agent is a 2:1 blend of emulsified water-based silver solution and zinc-pyrithione.

[0102] Dyes and / or pigments (such as titanium dioxide and / or carbon black), may be included in the additive component to impart color properties to the coating composition to tune reflective properties and / or UV protective properties. Pigments may be in the form of solids or a dispersion in a resin carrier. Suitable pigments include titanium dioxides, iron oxides, chromium (III) oxides, organic pigments, carbon black or anticorrosion pigments, phosphates, orthophosphates or polyphosphates containing, for example, chromium, zinc, aluminum, calcium, strontium or a combination of these metals as counterions. In an embodiment, the pigment is titanium dioxide.

[0103] Reinforcements (e.g., flake or milled glass and / or fumed silica), may be used to impart certain properties. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0104] The coating composition may be a curable composition that includes curing agent / hardener component in addition to the coating composition or as part of the coating composition. The amount of the hardener component used may vary depending on whether the hardener component is used in addition to or as part of the coating composition. In exemplary embodiments, an amine-based hardener (e.g., one that is known in the art for use in curing epoxy systems) may be excluded because the sprayable polyurethane systems rely on urethane curing chemistry due to minimal residual epoxy content.

[0105] In an embodiment, the oil resin is an epoxidized oil. The epoxidized oil may be derived from a synthetic and / or natural oil. In an embodiment, the epoxidized oil can be any suitable epoxidized oil obtained from a sustainable source. The sustainable source can be a plant oil, vegetable oil, tree oil, nut oil (which is different from (A)), or animal oil. In an embodiment of the present invention, the oil that can be epoxidized (directly or after dehydrogenation) is almond oil, avocado oil, bay oil, basil oil, bergamot oil, oils derived from biomass, Brazil nut oil, broccoli oil, cade oil, canola oil, caraway seed oil, cashew oil, cashew nutshell liquid, cinnamon leaf oil, citronella java oil, citrus seed oil, cod liver oil, com oil, cocoa butter, cottonseed oil, cumin oil, cypress oil, fish oil, flaxseed oil, geranium oil, grapefruit oil, hazelnut oil, lavender oil, lemongrass oil, linseed oil, macademia nut oil, mandarine oil, melissa oil, myrtle oil, neem oil, nutmeg oil, oat oil, olive oil, palm oil, palmarosa oil, peanut oil, pecan oil, peppermint oil, pine nut oil, pistachio oil, rapeseed oil, safflower oil, sage oil, sesame oil, soybean oil, spearmint oil, sunflower oil, high oleic sunflower oil, tea tree oil, thyme oil, triolein, vegetable oil, Vernonia oil, vetiver Haiti oil, walnut oil, wormwood oil, ylang ylang oil or any combination of two or more of the foregoing oils. In an embodiment, the epoxidized oil is epoxidized soybean oil.

[0106] In an embodiment, the bio-based starch additive is, for example, acorn squash starch, arrowroot starch, barley starch, butternut squash starch, cassava starch, corn starch (maize Attorney Docket No. BIOB-12 / 01WO 40787 / 64 starch), manioc starch, lentil starch, lima bean starch, oat starch, pea starch, potato starch, rice starch, sorghum starch, sweet potato starch, tapioca starch, wheat starch, white potato starch, or mixtures thereof. In an embodiment, the bio-based component is com starch. In an embodiment, the bio-based component is a potato starch.

[0107] Other additives include, e.g., UV light stabilizers, antioxidants, air release agents, and adhesion promoters, which may be independently used depending on the desired characteristics of the coating composition.

[0108] The additives addition amount will vary depending upon the end use. In an embodiment, the total amount of all additives (based on the total of the coating composition) is no more than 25 wt% no more than 20 wt%, no more than 15 wt%, not more than 10 wt%, or no more than 5 wt%. As an example, where the additive is a defoamer, the total amount is

[0109] 2 to 9 wt%, 3 to 8 wt%, or 4 to 7 wt%. Alternatively, where the coting composition contains a UV light stabilizer, the amount ranges from 1 to 4 wt% or 2 to 3 wt%. Where the coating composition contains a corrosion inhibitor, the amount ranges from 0.1 to 5 wt%, 0.5 to 4 wt%, 1 to 3 wt%, or 1.5 to 2.5 wt%. Where the coating composition contains an oil resin additive, the amount ranges from 0.1 to 5 wt%, 0.5 to 4 wt%, 1 to 3 wt%, or 1.5 to 2.5 wt%. Where the coating composition contains a bio-based starch additive, the amount ranges from

[0110] 1 to 20 wt%, 2.5 to 17.5 wt%, 5 to 15 wt%, 7.5 to 12.5 wt%, or 10 to 12 wt%.

[0111] Other exemplary additives and amounts include:

[0112] A reactive surfactant, for example 3-n-pentadecylphenol, with an equivalent weight of from 250 to 300, at an amount of from 1 to 5 wt% or 2 to 4 wt%.

[0113] A diamine with an equivalent weight ranging from 130 to 160, and an amount of from

[0114] 3 to 9 wt% or 5 to 7 wt%.

[0115] An antimicrobial agent, for example, silver solution and zinc pyrithione, at an amount of from 0.5 to 1.5 wt% or 0.75% to 1.25%. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0116] A comprehensive review of coatings additives is given in “Lehrbuch der Lacke und Beschichtungen [Textbook on paints and coatings], volume III, “Losemittel, Weichmacher, Additive, Zwischenprodukte” [Solvents, plasticizers, additives, intermediates], H. Kittel, Verlag W. A. Colomb in der Heenemann GmbH, Berlin-Oberschwandorf, 1976, pp. 237-398.

[0117] Properties and Attributes

[0118] In an embodiment, the coating composition has low VOC content or is free from (i.e., has zero) VOCs.

[0119] As low VOC content, it is envisioned that there is less than 2 wt%, less than 1.5 wt%, less than 1.0 wt%, less than 0.05 wt%, less than 0.01 wt% total VOCs.

[0120] In an embodiment, the coating composition has no detectable odor.

[0121] In an embodiment, the coating composition has a pH after mixing the components in a solvent ranging from 4.0 to 8.0, from 4.5 to 8.0, from 5.0 to 8.0, from 5.5 to 8.0, from 6.0 to 8.0, from 6.5 to 7.5, from 6.7 to 7.3, from 6.9 to 7.1.

[0122] In an embodiment, the coating composition has a dynamic viscosity at 25°C ranging from 800 to 4000 cps. As a lower viscosity limit, at least 800 cps, at least 850 cps, at least 900 cps, at least 950 cps, at least 1000 cps, at least 1100 cps, at least 1200 cps, at least 1300 cps, at least 1400 cps, at least 1500 cps, at least 1750 cps, and at least 2000 cps are mentioned. As an upper viscosity limit, at most 4000 cps, at most 3750 cps, at most 3500 cps, at most 3250 cps, at most 3000 cps, at most 2750 cps, at most 2500 cps, at most 2250 cps, and at most 2000 cps are mentioned. Ranges and sub-ranges based on a selection of a lower limit and an upper limit from the foregoing are mentioned. Exemplary viscosity ranges include formulations having a viscosity of 800 to 4000 cps, 1000 to 3500 cps, and 1200 to

[0123] 3000 cps. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0124] The coating composition contains a total of at least 24 wt%, at least 25 wt%, at least

[0125] 27.5 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 55 wt%, or at least 60 wt% of bio-based materials (e.g., the bio-based component as well as other plant-based and / or bio-renewable polymers). The coating composition contains a total of at most 95wt%, at most 90 wt%, at most 85 wt%, at most 80 wt%, at most 75 wt%, at most 70 wt%, at most 65 wt%, at most 60 wt%, at most 55 wt%, at most 50 wt%, at most 45 wt%, at most 40 wt%, or at most 35 wt% of bio-based materials (e.g., the bio-based component as well as other plant-based and / or bio-renewable polymers). In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include: 24 wt% to 95 wt%, 30 wt% to 95 wt%, 35 wt% to 95 wt%, 40 wt% to 95 wt%, 24 wt% to 85 wt%, 30 wt% to 85 wt%, 35 wt% to 85 wt%, 40 wt% to 85 wt%, 24 wt% to 75 wt%, 30 wt% to 75 wt%, 35 wt% to 75 wt%, 40 wt% to 75 wt%, 24 wt% to 65 wt%, 30 wt% to 65 wt%, 35 wt% to 65 wt%, 40 wt% to 65 wt%, 24 wt% to 50 wt%, 30 wt% to 50 wt%, 35 wt% to 50 wt%, and 40 wt% to 50 wt%.

[0126] In an embodiment, after mixing, the coating composition has a high solids content of over 25%, over 30%, over 35%, over 40%, over 45%, over 50%, over 55%, over 60%, over 70%, over 75%, over 80%, over 85%, or over 90%, for example from 25 to 95%, from 30 to 90%, from 35 to 80%, from 40 to 70%, from 45 to 65%. This very high solids content reduces transportation costs.

[0127] The coating composition of the present invention can be formulated in various forms, such as liquids, pastes, films, depending on the desired application method. The coating is designed to be easily applied to the substrates, either manually or through automated dispensing equipment. Upon application, the coating cures at ambient temperatures, forming a strong and lasting bond to the surface upon which it is applied. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0128] Kits

[0129] The present invention includes an embodiment where a kit is provided such that the coating composition described above is present together with instructions for preparing and / or using the coating composition.

[0130] In the kits of the present invention, one or more of (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives may be stored in its own individual container or stored in a container in combination with any one or more of the other component(s).

[0131] In the kits of the present invention, additives may be present. In an embodiment the additives are present in the coating composition. Alternatively, the additives may be contained in their own separate container(s) for addition as applicable to the desired use. For example, dyes and / or pigments may be stored in a separate container in the kit.

[0132] Storage temperatures for the kit should be 45° to 90°F, 55° to 85°F, or 60° to 80°F. Freezing temperatures, direct sunlight, & moisture should be avoided. Further, the kit should not be exposed to direct heat and / or should be kept away from heat sources.

[0133] In an embodiment, the coating composition is contained in a delivery device. In an embodiment the delivery device may contain the coating composition and a curing agent in separate chambers of a delivery device, wherein each container is connected to a mixing chamber by way of a tube, a channel, or other delivery vehicle.

[0134] In an embodiment, the delivery device further comprises a tip, tube, channel or other outlet for application of the coating to the desired surface.

[0135] Method of Preparing a Coating Composition Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0136] In an embodiment, the coating composition is prepared by: stirring, shaking, or agitating (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives, for a time and under conditions sufficient to blend (A) the water-based epoxy resin,

[0137] (B) the bio-based hardener, and (C) the one or more additives to substantial homogeneity thus forming the coating composition.

[0138] In an embodiment, a solvent is present and the solvent has low or is free from volatile organic compounds.

[0139] In an embodiment, (A) the water-based epoxy resin, (B) the bio-based hardener, and

[0140] (C) the one or more additives may be added in any order.

[0141] In an embodiment, all components are added together and the mixture is then stirred, shaken, or agitated. In this embodiment, one or more components may be dissolved in sufficient solvent to permit formation of a substantially homogenous dissolution or suspension.

[0142] In an embodiment, (A) the water-based epoxy resin is dissolved in sufficient solvent to permit formation of a substantially homogenous dissolution or suspension followed by addition, in any order, individually or together, (B) the bio-based hardener and (C) the one or more additives. In an embodiment, components (B) and (C) are pre-mixed before addition to component (A).

[0143] In an embodiment, (B) the bio-based hardener is dissolved in sufficient solvent to permit formation of a substantially homogenous dissolution or suspension followed by addition, in any order, individually or together, (A) the water-based epoxy resin and (C) the one or more additives. In an embodiment, components (A) and (C) are pre-mixed before addition to component (B).

[0144] In an embodiment, (C) the one or more additives is dissolved in sufficient solvent to permit formation of a substantially homogenous dissolution or suspension followed by Attorney Docket No. BIOB-12 / 01WO 40787 / 64 addition, in any order, individually or together, (A) the water-based epoxy resin and (B) the bio-based hardener. In an embodiment, components (A) and (B) are pre-mixed before addition to component (C).

[0145] In the method of the present invention, the component(s) and mixtures thereof are stirred, shaken, or agitated for a time and under conditions suitable to fully disperse the component(s).

[0146] The time and conditions for stirring, shaking, or agitating (i.e., mixing) is not particularly limited so long as it is sufficient to ensure that (A) the water-based epoxy resin, (B) the bio-based hardener, and (C) the one or more additives, respectively, are fully dispersed (e.g., in a solvent). The time and conditions would be understood to the skilled artisan. Exemplary, times are from 15 seconds to 5 minutes, from 30 seconds to 4 minutes, from 1 minute to 3 minutes. Stirring can be accomplished by using a jiffy blade mixer at a slow speed (e.g., 400 rpm, 450 rpm, 500 rpm, 550 rpm, 600 rpm). Alternatively, hand shaking or agitation may be used.

[0147] “Substantially homogeneity” or “substantially homogeneous” in this context means that the (A) the water-based epoxy resin, (B) the bio-based hardener, and (C) the one or more additives, as applicable, are mixed well and in a manner that permits creation of an approximately uniform dispersion. In an embodiment, the total mixing time is from 30 seconds to 5 minutes, from 1 minute to 4 minutes, from 2 minutes to 3 minutes.

[0148] In the preparation method above, the coating composition may optionally be allowed stand for a time ranging from 30 seconds to 5 minutes, from 1 minute to 4 minutes, from 2 minutes to 3 minutes prior to being applied to a surface of a material.

[0149] In an embodiment, the coating composition has low VOC content or is free from (i.e., has zero) VOCs. As low VOC content, it is envisioned that there is less than 2 wt%, less than 1.5 wt%, less than 1.0 wt%, less than 0.05 wt%, less than 0.01 wt% total VOCs. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0150] In an embodiment, the coating composition has no detectable odor after mixing.

[0151] In an embodiment, the coating composition has a pH after mixing ranging from 4.0 to 8.0, from 4.5 to 8.0, from 5.0 to 8.0, from 5.5 to 8.0, from 6.0 to 8.0, from 6.5 to 7.5, from 6.7 to 7.3, from 6.9 to 7.1.

[0152] In an embodiment, the coating composition has a dynamic viscosity at 25°C after mixing ranging from 800 to 4000 cps. As a lower viscosity limit, at least 800 cps, at least 850 cps, at least 900 cps, at least 950 cps, at least 1000 cps, at least 1100 cps, at least 1200 cps, at least 1300 cps, at least 1400 cps, at least 1500 cps, at least 1750 cps, and at least 2000 cps are mentioned. As an upper viscosity limit, at most 4000 cps, at most 3750 cps, at most 3500 cps, at most 3250 cps, at most 3000 cps, at most 2750 cps, at most 2500 cps, at most 2250 cps, and at most 2000 cps are mentioned. Ranges and sub-ranges based on a selection of a lower limit and an upper limit from the foregoing are mentioned. Exemplary viscosity ranges include formulations having a viscosity of 800 to 4000 cps, 1000 to 3500 cps, and 1200 to 3000 cps.

[0153] The coating composition contains a total of at least 24%, at least 25 wt%, at least 27.5 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 55 wt%, or at least 60 wt% of bio-based materials (e.g., a plant-based and / or biorenewable polymer). The coating composition contains a total of at most 95wt%, at most 90 wt%, at most 85 wt%, at most 80 wt%, at most 75 wt%, at most 70 wt%, at most 65 wt%, at most 60 wt%, at most 55 wt%, at most 50 wt%, at most 45 wt%, at most 40 wt%, or at most 35 wt% of bio-based materials (e.g., a plant-based and / or bio-renewable materials). In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include: 24 wt% to 95 wt%, 30 wt% to 95 wt%, 35 wt% to 95 wt%, 40 wt% to 95 wt%, 24 wt% to 85 wt%, 30 wt% to 85 wt%, 35 wt% to 85 wt%, 40 wt% to 85 wt%, 24 wt% to 75 wt%, 30 wt% to 75 Attorney Docket No. BIOB-12 / 01WO 40787 / 64 wt%, 35 wt% to 75 wt%, 40 wt% to 75 wt%, 24 wt% to 65 wt%, 30 wt% to 65 wt%, 35 wt% to 65 wt%, 40 wt% to 65 wt%, 24 wt% to 50 wt%, 30 wt% to 50 wt%, 35 wt% to 50 wt%, and 40 wt% to 50 wt%.

[0154] In an embodiment, after mixing, the coating composition has a high solids content of over 25%, over 30%, over 35%, over 40%, over 45%, over 50%, over 55%, over 60%, over 70%, over 75%, over 80%, over 85%, or over 90%, for example from 25 to 95%, from 30 to 90%, from 35 to 80%, from 40 to 70%, from 45 to 65%. This very high solids content reduces transportation costs.

[0155] Method of Using the Coating Composition and Resulting Material Construct

[0156] In an embodiment is a method of coating a surface of a material by:

[0157] (1) applying a layer of a coating composition comprising (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives to a surface of a material, wherein the material, and

[0158] (2) allowing the coating composition to cure.

[0159] Depending upon the surface to be treated, the application method, and the desired application thickness, among other factors, the coating composition of the present invention may be diluted by up to 50% (i.e., add an equal amount of solvent to the volume of the mixed coating composition), up to 40%, up to 30%, up to 25%, up to 20%, up to 15%, or up to 10% with a solvent. In this regard, there would be a corresponding decrease in the solids content of the coating composition to be applied. Thinning by dilution may be desirable for some applications to avoid lap marks and / or to allow for proper self-leveling characteristics. In an embodiment, the solvent has low VOC content or is free from (i.e., has zero) VOCs. The solvent for dissolution may be water. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0160] The coating composition of the present invention may be applied directly to a surface of a material.

[0161] Application of the coating composition can be in one coating layer or multiple coating layers.

[0162] Overall, the total application and / or dry film thickness may be at least 0.001 inches (1 mil), at least 0.002 inches (2 mils), at least 0.003 inches (3 mils), at least 0.004 inches (4 mils), at least 0.005 inches (5 mils), at least 0.006 inches (6 mils), at least 0.007 inches (7 mils), at least 0.008 inches (8 mils), at least 0.009 inches (9 mils), at least 0.010 inches (10 mils), at least 0.011 inches (11 mils), at least 0.012 inches (12 mils), at least 0.013 inches (13 mils), at least 0.014 inches (14 mils), at least 0.015 inches (15 mils), at least 0.016 inches (16 mils), at least 0.017 inches (17 mils), at least 0.018 inches (18 mils), at least 0.019 inches (19 mils), at least 0.020 inches (20 mils), at least 0.021 inches (21 mils), at least 0.022 inches (22 mils), at least 0.023 inches (23 mils), at least 0.024 inches (24 mils), at least 0.025 inches (25 mils), at least 0.026 inches (26 mils), at least 0.027 inches (27 mils), at least 0.028 inches (28 mils), at least 0.029 inches (29 mils), at least 0.030 inches (30 mils), at least 0.031 inches (31 mils), at least 0.032 inches (32 mils), at least 0.033 inches (33 mils), at least 0.034 inches (34 mils), at least 0.035 inches (35 mils), at least 0.036 inches (36 mils), at least 0.037 inches (37 mils), at least 0.038 inches (38 mils), at least 0.039 inches (39 mils), at least 0.040 inches (40 mils), at least 0.050 inches (50 mils), at least 0.060 inches (60 mils), at least 0.070 inches (70 mils), at least 0.080 inches (80 mils), at least 0.090 inches (90 mils), or at least 0.100 inches (100 mils). Overall, the total thickness may be at most 0.500 inches (500 mils), at most 0.400 inches (400 mils), at most 0.300 inches (300 mils), at most 0.250 inches (250 mils), at most 0.200 inches (200 mils), at most 0.150 inches (150 mils), at most 0.100 inches (100 mils), at most 0.090 inches (90 mils), at most 0.080 inches (80 mils), at most 0.070 inches (70 mils), at most 0.060 inches (60 mils), at most 0.050 inches (50 mils), at most 0.049 inches (49 mils), at Attorney Docket No. BIOB-12 / 01WO 40787 / 64 most 0.048 inches (48 mils), at most 0.047 inches (47 mils), at most 0.046 inches (46 mils), at most 0.045 inches (45 mils), at most 0.044 inches (44 mils), at most 0.043 inches (43 mils), at most 0.042 inches (42 mils), at most 0.041 inches (41 mils), at most 0.040 inches (40 mils), at most 0.039 inches (39 mils), at most 0.038 inches (38 mils), at most 0.037 inches (37 mils), at most 0.036 inches (36 mils), at most 0.035 inches (35 mils), at most 0.034 inches (34 mils), at most 0.033 inches (33 mils), at most 0.032 inches (32 mils), at most 0.031 inches (31 mils), or at most 0.030 inches (30 mils). Ranges and sub-ranges based on a selection of a lower limit and an upper limit from the foregoing are included in the present invention. Exemplary thickness ranges include coating thicknesses of from 0.001 to 0.500 inches (1 - 500 mils), from 0.002 to 0.250 inches (2 - 250 mils), from 0.003 to 0.200 inches (3 - 200 mils), from 0.004 to 0.100 inches (4 to 100 mils), from 0.005 to 0.050 inches (5 to 50 mils) or from 0.010 to 0.040 inches (10 to 40 mils).

[0163] Where multiple layers (i.e., applications) are used, the application thickness per layer may be 1 to 50 mils, 2 to 45 mils, 3 to 40 mils, 4 to 35 mils, 5 to 30 mils, 5 to 25 mils, 5 to 20 mils, 5 to 15 mils, or 5 to 10 mils. Of course, thinner coating ranges are also envisioned by selecting any lower and upper limit from the foregoing including, for example, from 1 to 10 mils, 2 to 10 mils, 2 to 15 mils, 2 to 20 mils, 3 to 10 mils, 3 to 15 mils, 3 to 20 mils, 4 to 10 mils, 4 to 15 mils, or 4 to 20 mils. Where multiple layers are used, there are at least 2, at least 3, at least 4, or least 5 layers to at most 10 layers, at most 9 layers, at most 8 layers, at most 7 layers, at most 6 layers, or at most 5 layers. Illustrative exemplary ranges including 2 to 10 layers, 2 to 8 layers, 2 to 5 layer, 3 to 10 layers, 3 to 8 layer, and 3 to 5 layers.

[0164] The coating composition may be applied to the surface of a material by brushing, rolling, or spraying.

[0165] The coating composition of the present invention has a coverage rate of approximately 250 to 400 sq. ft. per gallon; however, the coverage rate is impacted by the Attorney Docket No. BIOB-12 / 01WO 40787 / 64 material (e.g., substrate) to be treated, the surface pretreatment, and whether or not the coating composition was diluted before application. The following table includes approximate coverage rates for different substrates: Following application to the surface of a material, the coating composition of the present invention has a dry-time ranging from 2 to 15 hours, from 3 to 14 hours, from 4 to 13 hours, from 5 to 12 hours, from 6 to 11 hours, or from 7 to 10 hours, but the drying time varies depending upon the temperature, ventilation, and catalyst system being used. For example, the drying time at ambient temperature may be 8 hours or less. After preparing the coating composition, a process for curing the composition may be used to form a thermoset or cured composition. For example, the composition or formulation may be cured under conventional processing conditions to form a coating bond. Curing the coating composition may be carried out at curing reaction conditions including a predetermined temperature and for a predetermined period of time sufficient to cure the composition. The curing conditions may be dependent on the various components used in the curable composition such as the hardener used in the formulation. The curing reaction conditions include, e.g., carrying out the reaction under a temperature, generally in the range of from -5° C. to 60° C. (e.g., 0° C. to 50° C„ 5° C. to 45° C„ 10° C. to 35° C„ 15° C. to 30° Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0166] C., 20° C. to 27.5° C. etc.), including ambient temperature. For sprayable applications, the coating may be applied to substrates, e.g., using airless sprayers and air-assisted pneumatic sprayers and the like. The applied composition may be cured by heating the composition at the aforementioned curing temperatures.

[0167] Following drying of a first layer or when the coating is tack free, a second coating layer may be applied by spraying, rolling, or brushing (which may be repeated for additional layers). However, for proper adhesion, it is desired to apply the second (or subsequent) coat within 24 hours, within 18 hours, within 12 hours, or within 6 hours of application of the first (or prior) coat. If the first (or prior) coat has dried longer than 24-hours, the surface may be abraded or etched to promote adhesion of the second (or subsequent) coat.

[0168] Temperature and humidity directly affect pot life and dry time. Accordingly, in an embodiment the conditions should be between 40 - 95 °F, between 50 and 85 °F, between 60 and 80 °F, or between 65 and 75 °F and the humidity should not exceed 80%, not exceed 70%, not exceed 60%, or not exceed 50%.

[0169] In an embodiment, the surface to be coated has a moisture content of no more than 25%, no more than 20%, no more than 15%, no more than 10%, or no more than 5% as measured with an electronic moisture meter.

[0170] Prior to application of the coating composition to a surface(s), the surface(s) may pretreated and / or cleaned.

[0171] In an embodiment, the surface(s) to be adhered may be cleaned prior to application of the coating composition. For example, to facilitate proper adherence, the surface can be cleaned to remove dirt, debris, grime, minerals such as lime and calcium, oils, release agents, grease, mud, excess mortar, and mold and mildew, etc.

[0172] In an embodiment, the surface may be pretreated with a primer (e.g., smooth surfaces) or a sealer or filler to remove pinholes (e.g., porous surfaces). Another envisioned Attorney Docket No. BIOB-12 / 01WO 40787 / 64 pretreatment includes pointing and / or caulking all cracks. Further, all voids, beeholes, masonry surface defects and openings such as conduits, pipes, drains, door frames, vents, air conditioner openings, electrical openings, control joints, or any dissimilar materials should be repaired using urethane or other approved patching.

[0173] Another form of surface pretreatment envisioned in the present invention includes fluting, scoring, sandblasting, and / or etching as well as raking joints. Pretreating a surface in this manner can increase the absorption, but will also lower coverage rates.

[0174] In an embodiment, the coating composition is not applied where freezing temperatures have existed prior to application. In such a situation, adequate time should be allowed for the application surface to thaw. In an embodiment, air, surface, and material temperatures should be above 40°F (4.4°C) and at least 5°F above the dew point prior to application. Further, it is not desirable to apply the coating composition where temperatures are below 40°F or when temperatures are expected to drop below 40°F within 48 hours of application. For exterior surfaces, application should also be avoided if rain, snow, or lower temperatures are expected within 48 hours. Further, the coating composition would be adversely affective if relative humidity is greater than 90% and, therefore, it should be avoided.

[0175] In the case of spills or following application excess coating composition can be cleaned up with water.

[0176] Coated Products

[0177] The coating composition of the present invention may find utility in many different industries including oil and gas, steel fabrication, bridge and highway, power generation, marine, food processing, pharmaceutical, veterinary, hospitals, and restaurants. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0178] An exemplary use includes roofs (including asphalt shingles, metal roofs, concrete roofs, and concrete tiles, etc.), floors (concrete, ceramic, wood, metal, galvanized steel, ungalvanized steel, tile, etc.) in several industries including food processing, veterinary, hospitals, restaurants and other facilities. Other uses include warehouses, food and beverage facilities, USDA inspected facilities, commercial vehicles, airports, stadiums, sound walls, stadiums, direct-to-metal, direct-to-aluminum, direct-to-galvanized steel, direct-to- ungalvanized steel.

[0179] Thus, the coating composition is suitable for and has excellent adherence properties with a broad scope of materials including asphalt, ceramic, glass, concrete, wood, metal, galvanized steel, ungalvanized steel, tile, paper packaging (e.g., cardboard), composites, textile and plastic.

[0180] Within the scope of the present invention are materials having a coating made from the coating composition of the present invention. In an embodiment, the coating on the materials is at a total dry film thickness of at least 0.001 inches (1 mil), at least 0.002 inches (2 mils), at least 0.003 inches (3 mils), at least 0.004 inches (4 mils), at least 0.005 inches (5 mils), at least 0.006 inches (6 mils), at least 0.007 inches (7 mils), at least 0.008 inches (8 mils), at least 0.009 inches (9 mils), at least 0.010 inches (10 mils), at least 0.011 inches (11 mils), at least 0.012 inches (12 mils), at least 0.013 inches (13 mils), at least 0.014 inches (14 mils), at least 0.015 inches (15 mils), at least 0.016 inches (16 mils), at least 0.017 inches (17 mils), at least 0.018 inches (18 mils), at least 0.019 inches (19 mils), at least 0.020 inches (20 mils), at least 0.021 inches (21 mils), at least 0.022 inches (22 mils), at least 0.023 inches (23 mils), at least 0.024 inches (24 mils), at least 0.025 inches (25 mils), at least 0.026 inches (26 mils), at least 0.027 inches (27 mils), at least 0.028 inches (28 mils), at least 0.029 inches (29 mils), at least 0.030 inches (30 mils), at least 0.031 inches (31 mils), at least 0.032 inches (32 mils), at least 0.033 inches (33 mils), at least 0.034 inches (34 mils), at least 0.035 inches (35 Attorney Docket No. BIOB-12 / 01WO 40787 / 64 mils), at least 0.036 inches (36 mils), at least 0.037 inches (37 mils), at least 0.038 inches (38 mils), at least 0.039 inches (39 mils), at least 0.040 inches (40 mils), at least 0.050 inches (50 mils), at least 0.060 inches (60 mils), at least 0.070 inches (70 mils), at least 0.080 inches (80 mils), at least 0.090 inches (90 mils), or at least 0.100 inches (100 mils). Overall, the total thickness may be at most 0.500 inches (500 mils), at most 0.400 inches (400 mils), at most 0.300 inches (300 mils), at most 0.250 inches (250 mils), at most 0.200 inches (200 mils), at most 0.150 inches (150 mils), at most 0.100 inches (100 mils), at most 0.090 inches (90 mils), at most 0.080 inches (80 mils), at most 0.070 inches (70 mils), at most 0.060 inches (60 mils), at most 0.050 inches (50 mils), at most 0.049 inches (49 mils), at most 0.048 inches (48 mils), at most 0.047 inches (47 mils), at most 0.046 inches (46 mils), at most 0.045 inches (45 mils), at most 0.044 inches (44 mils), at most 0.043 inches (43 mils), at most 0.042 inches (42 mils), at most 0.041 inches (41 mils), at most 0.040 inches (40 mils), at most 0.039 inches (39 mils), at most 0.038 inches (38 mils), at most 0.037 inches (37 mils), at most 0.036 inches (36 mils), at most 0.035 inches (35 mils), at most 0.034 inches (34 mils), at most 0.033 inches (33 mils), at most 0.032 inches (32 mils), at most 0.031 inches (31 mils), or at most 0.030 inches (30 mils). Ranges and sub-ranges based on a selection of a lower limit and an upper limit from the foregoing are included in the present invention. Exemplary thickness ranges include coating thicknesses of from 0.001 to 0.500 inches (1 - 500 mils), from 0.002 to 0.250 inches (2 - 250 mils), from 0.003 to 0.200 inches (3 - 200 mils), from 0.004 to 0.100 inches (4 to 100 mils), from 0.005 to 0.050 inches (5 to 50 mils) or from 0.010 to 0.040 inches (10 to 40 mils).

[0181] Therefore, within the scope of the present invention is a material having a coating as defined that has low or is free from volatile organic compounds and the thickness has at least 24 wt% of the bio-based component based on the total solids content of the coating. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0182] Benefits of Adhesive

[0183] In some embodiments, the adhesive composition of the present invention provides one or more of the following advantages over conventional epoxy-based coatings:

[0184] • Environmentally Friendly: Reduced reliance on petrochemicals and lower VOC content compared to conventional epoxies.

[0185] • Enhanced Durability: Surprisingly, this bio-based epoxy exhibits durability comparable to or exceeding petroleum-based counterparts, particularly in terms of water resistance, impact resistance, and tensile strength.

[0186] • Water-Based: Easier to handle, clean up, and apply, reducing health and safety risks associated with solvent-based epoxies.

[0187] • Versatile Applications: Suitable for a wide range of applications, including adhesives, coatings, composites, and encapsulants.

[0188] Exemplary embodiments of the present invention include:

[0189] [1] A coating composition comprising:

[0190] (A) a water-based epoxy resin;

[0191] (B) bio-based hardener; and

[0192] (C) one or more additives.

[0193] [2] The coating composition of [1], wherein (C) is a solvent.

[0194] [3] The coating composition of [2], wherein the solvent has low volatile organic compounds content.

[0195] [4] The coating composition of [2] or [3], wherein the solvent is free of volatile organic compounds.

[0196] [5] The coating composition of any one of [2] - [4], wherein the solvent is water. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0197] [6] The coating composition of any one of [1] - [5], wherein the coating composition has low volatile organic compounds content.

[0198] [7] The coating composition of any one of [1] - [6], wherein the coating composition is free of volatile organic compounds.

[0199] [8] The coating composition of any one of [1] - [7], wherein the composition has a pH ranging from 4.0 to 8.0.

[0200] [9] The coating composition of any one of [1] - [8], wherein the composition has a dynamic viscosity at 25°C ranging from 800 to 4000 cps.

[0201]

[0010] The coating composition of any one of [1] - [9], wherein (A) is selected from the group consisting of an epoxidized oil, an epoxidized natural rubber, and a modified plantbased starch with an epoxy functionality.

[0202]

[0011] The coating composition of any one of [1] -

[0010] , wherein (A) is an epoxidized soybean oil or an epoxidized linseed oil.

[0203]

[0012] The coating composition of any one of [1] -

[0011] , wherein the coating composition comprises from 30 to 75 wt% of component (A).

[0204]

[0013] The coating composition of any one of [1] -

[0012] , wherein (B) is a nut oil modified to contain an amine functionality.

[0205]

[0014] The coating composition of any one of [1] -

[0013] , wherein (B) is a phenylalkamine or phenylalkamide of a nut oil.

[0206]

[0015] The coating composition of any one of

[0013] -

[0014] , wherein the nut oil is one or more selected from the group consisting of almond oil, argan oil, avocado oil, Brazil nut oil, cashew oil, cashew nutshell liquid, groundnut oil, hazelnut oil, macademia nut oil, nutmeg oil, pecan oil, pine nut oil, pistachio oil, and walnut oil.

[0207]

[0016] The coating composition of any one of [1] -

[0015] , wherein (B) is a phenylalkamine or phenylalkamide of a cardanol compound. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0208]

[0017] The coating composition of any one of [1] -

[0016] , wherein the coating composition comprises from 10 to 20 wt% of component (B).

[0209]

[0018] The coating composition of any one of [1] -

[0017] , wherein (C) is selected from the group consisting of a solvent, a filler, a plasticizer, a stabilizer, and an other additive or a mixture thereof.

[0210]

[0019] The coating composition of any one of [1] -

[0018] , wherein the other additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a filler, a reinforcement, a chain extender, a corrosion inhibitor, an oil resin (e.g., soy oil resin), a bio-based starch, and a crosslinker.

[0211]

[0020] The coating composition of any one of [1] -

[0019] , wherein (C) is a filler.

[0212]

[0021] The coating composition of any one of [1] -

[0020] , wherein (C) is a bio-based filler.

[0213]

[0022] The coating composition of any one of [1] -

[0021] , wherein (C) is a plasticizer.

[0214]

[0023] The coating composition of any one of [1] -

[0022] , wherein (C) is a bio-based plasticizer.

[0215]

[0024] The coating composition of any one of [1] -

[0023] , wherein (C) is a stabilizer.

[0216]

[0025] The coating composition of any one of [1] -

[0024] , wherein the coating composition has 24 wt% to 95 wt% bio-based materials.

[0217]

[0026] A kit comprising, the coating composition of any one of [1] -

[0025] together with instructions for use thereof.

[0218]

[0027] The kit of

[0026] , wherein one or more of (A), (B), and (C) are separately packaged. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0219]

[0028] The kit of

[0026] or

[0027] , wherein the coating composition is contained in a delivery device.

[0220]

[0029] A method of making a coating composition, comprising stirring, shaking, or agitating (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives for a time and under conditions sufficient to blend the (A) the water-based epoxy resin, (B) the bio-based hardener, and (C) the one or more additives to substantial homogeneity thus forming the coating composition.

[0221]

[0030] The method of

[0029] , wherein (C) comprises a solvent.

[0222]

[0031] The method of

[0030] , wherein the solvent has low volatile organic compounds content.

[0223]

[0032] The method of

[0030] or

[0031] , wherein the solvent is free of volatile organic compounds.

[0224]

[0033] The method of any one of

[0030] -

[0032] , wherein the solvent is water.

[0225]

[0034] The method of any one of

[0029] -

[0033] , wherein the coating composition has low volatile organic compounds content.

[0226]

[0035] The method of any one of

[0029] -

[0034] , wherein the coating composition is free of volatile organic compounds.

[0227]

[0036] The method of any one of

[0029] -

[0035] , wherein the composition has a pH ranging from 4.0 to 8.0.

[0228]

[0037] The method of any one of

[0029] -

[0036] , wherein the composition has a dynamic viscosity at 25°C ranging from 800 to 4000 cps.

[0229]

[0038] The method of any one of

[0029] -

[0037] , wherein (A) is selected from the group consisting of an epoxidized oil, an epoxidized natural rubber, and a modified plant-based starch with an epoxy functionality. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0230]

[0039] The method of any one of

[0029] -

[0038] , wherein (A) is an epoxidized soybean oil or an epoxidized linseed oil.

[0231]

[0040] The method of any one of

[0029] -

[0039] , wherein the coating composition comprises from 30 to 75 wt% of component (A).

[0232]

[0041] The method of any one of

[0029] -

[0040] , wherein (B) is a nut oil modified to contain an amine functionality.

[0233]

[0042] The method of any one of

[0029] -

[0041] , wherein (B) is a phenylalkamine or phenylalkamide of a nut oil.

[0234]

[0043] The method of any one of

[0041] -

[0042] , wherein the nut oil is one or more selected from the group consisting of almond oil, argan oil, avocado oil, Brazil nut oil, cashew oil, cashew nutshell liquid, groundnut oil, hazelnut oil, macademia nut oil, nutmeg oil, pecan oil, pine nut oil, pistachio oil, and walnut oil.

[0235]

[0044] The method of any one of

[0029] -

[0043] , wherein (B) is a phenylalkamine or phenylalkamide of a cardanol compound.

[0236]

[0045] The method of any one of

[0029] -

[0044] , wherein the coating composition comprises from 10 to 20 wt% of component (B).

[0237]

[0046] The method of any one of

[0029] -

[0045] , wherein (C) is selected from the group consisting of a solvent, a filler, a plasticizer, a stabilizer, and an other additive or a mixture thereof.

[0238]

[0047] The method of any one of

[0029] -

[0046] , wherein the other additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a filler, a reinforcement, a chain Attorney Docket No. BIOB-12 / 01WO 40787 / 64 extender, a corrosion inhibitor, an oil resin (e.g., soy oil resin), a bio-based starch, and a crosslinker.

[0239]

[0048] The method of any one of

[0029] -

[0047] , wherein (C) is a filler.

[0240]

[0049] The method of any one of

[0029] -

[0048] , wherein (C) is a bio-based filler.

[0241]

[0050] The method of any one of

[0029] -

[0049] , wherein (C) is a plasticizer.

[0242]

[0051] The method of any one of

[0029] -

[0050] , wherein (C) is a bio-based plasticizer.

[0243]

[0052] The method of any one of

[0029] -

[0051] , wherein (C) is a stabilizer.

[0244]

[0053] The method of any one of

[0029] -

[0052] , wherein the coating composition has 24 wt% to 95 wt% bio-based materials.

[0245]

[0054] A method of coating a surface of a material by:

[0246] (1) applying a layer of a coating composition comprising (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives to a surface of a material, wherein the material, and

[0247] (2) allowing the coating composition to cure.

[0248]

[0055] The method of

[0054] , wherein (1) and (2) are repeated to form layers of the coating composition.

[0249]

[0056] The method of

[0055] , wherein there are 2 to 5 layers.

[0250]

[0057] The method of any one of

[0054] -

[0056] , wherein the total thickness of the coating composition after said applying ranges from 1 to 500 mils.

[0251]

[0058] The method of any one of

[0054] -

[0057] , wherein the total thickness of the coating composition after said applying ranges from 5 to 50 mils.

[0252]

[0059] The method of any one of

[0054] -

[0058] , wherein said allowing the coating composition to cure is at ambient temperature.

[0253]

[0060] The method of any one of

[0054] -

[0059] , wherein (C) comprises a solvent. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0254]

[0061] The method of any one of

[0054] -

[0060] , wherein the solvent has low volatile organic compounds content.

[0255]

[0062] The method of any one of

[0054] -

[0061] , wherein the solvent is free of volatile organic compounds.

[0256]

[0063] The method of any one of

[0054] -

[0062] , wherein the solvent is water.

[0257]

[0064] The method of any one of

[0054] -

[0063] , wherein the coating composition has low volatile organic compounds content.

[0258]

[0065] The method of any one of

[0054] -

[0064] , wherein the coating composition is free of volatile organic compounds.

[0259]

[0066] The method of any one of

[0054] -

[0065] , wherein the composition has a pH ranging from 4.0 to 8.0.

[0260]

[0067] The method of any one of

[0054] -

[0066] , wherein the composition has a dynamic viscosity at 25°C ranging from 800 to 4000 cps.

[0261]

[0068] The method of any one of

[0054] -

[0067] , wherein (A) is selected from the group consisting of an epoxidized oil, an epoxidized natural rubber, and a modified plant-based starch with an epoxy functionality.

[0262]

[0069] The method of any one of

[0054] -

[0068] , wherein (A) is an epoxidized soybean oil or an epoxidized linseed oil.

[0263]

[0070] The method of any one of

[0054] -

[0069] , wherein the coating composition comprises from 30 to 75 wt% of component (A).

[0264]

[0071] The method of any one of

[0054] -

[0070] , wherein (B) is a nut oil modified to contain an amine functionality.

[0265]

[0072] The method of any one of

[0054] -

[0071] , wherein (B) is a phenylalkamine or phenylalkamide of a nut oil. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0266]

[0073] The method of any one of

[0071] -

[0072] , wherein the nut oil is one or more selected from the group consisting of almond oil, argan oil, avocado oil, Brazil nut oil, cashew oil, cashew nutshell liquid, groundnut oil, hazelnut oil, macademia nut oil, nutmeg oil, pecan oil, pine nut oil, pistachio oil, and walnut oil.

[0267]

[0074] The method of any one of

[0054] -

[0073] , wherein (B) is a phenylalkamine or phenylalkamide of a cardanol compound.

[0268]

[0075] The method of any one of

[0054] -

[0074] , wherein the coating composition comprises from 10 to 20 wt% of component (B).

[0269]

[0076] The method of any one of

[0054] -

[0075] , wherein (C) is selected from the group consisting of a solvent, a filler, a plasticizer, a stabilizer, and an other additive or a mixture thereof.

[0270]

[0077] The method of any one of

[0054] -

[0076] , wherein the other additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a filler, a reinforcement, a chain extender, a corrosion inhibitor, an oil resin (e.g., soy oil resin), a bio-based starch, and a crosslinker.

[0271]

[0078] The method of any one of

[0054] -

[0077] , wherein (C) is a filler.

[0272]

[0079] The method of any one of

[0054] -

[0078] , wherein (C) is a bio-based filler.

[0273]

[0080] The method of any one of

[0054] -

[0079] , wherein (C) is a plasticizer.

[0274]

[0081] The method of any one of

[0054] -

[0080] , wherein (C) is a bio-based plasticizer.

[0275]

[0082] The method of any one of

[0054] -

[0081] , wherein (C) is a stabilizer.

[0276]

[0083] The method of any one of

[0029] -

[0082] , wherein the coating composition has 24 wt% to 95 wt% bio-based materials. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0277]

[0084] A coated material wherein a surface of a material has a coating of a cured product of a coating composition comprising (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives.

[0278]

[0085] The coated material of

[0084] , wherein the coating has at least 24 wt% of bio-based components based on the total solids content of the coating.

[0279]

[0086] The material construct of

[0084] or

[0085] , wherein the material is selected from the group consisting of asphalt, ceramic, glass, concrete, wood, metal, galvanized steel, ungalvanized steel, tile, paper packaging, composites, textile and plastic.

[0280]

[0087] The material construct of any one of

[0084] -

[0086] , wherein the total thickness of the coating ranges from 1 to 500 mils.

[0281]

[0088] The material construct of any one of

[0084] -

[0087] , wherein the total thickness of the coating ranges from 5 to 50 mils.

[0282]

[0089] The material construct of any one of

[0084] -

[0088] , wherein (C) comprises a solvent.

[0283]

[0090] The material construct of any one of

[0084] -

[0089] , wherein the solvent has low volatile organic compounds content.

[0284]

[0091] The material construct of any one of

[0084] -

[0090] , wherein the solvent is free of volatile organic compounds.

[0285]

[0092] The material construct of any one of

[0084] -

[0091] , wherein the solvent is water.

[0286]

[0093] The material construct of any one of

[0084] -

[0092] , wherein the coating composition has low volatile organic compounds content.

[0287]

[0094] The material construct of any one of

[0084] -

[0093] , wherein the coating composition is free of volatile organic compounds.

[0288]

[0095] The material construct of any one of

[0084] -

[0094] , wherein the composition has a pH ranging from 4.0 to 8.0. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0289]

[0096] The material construct of any one of

[0084] -

[0095] , wherein the composition has a dynamic viscosity at 25°C ranging from 800 to 4000 cps.

[0290]

[0097] The material construct of any one of

[0084] -

[0096] , wherein (A) is selected from the group consisting of an epoxidized oil, an epoxidized natural rubber, and a modified plantbased starch with an epoxy functionality.

[0291]

[0098] The material construct of any one of

[0084] -

[0097] , wherein (A) is an epoxidized soybean oil or an epoxidized linseed oil.

[0292]

[0099] The material construct of any one of

[0084] -

[0098] , wherein the coating composition comprises from 30 to 75 wt% of component (A).

[0293]

[0100] The material construct of any one of

[0084] -

[0099] , wherein (B) is a nut oil modified to contain an amine functionality.

[0294]

[0101] The material construct of any one of

[0084] -

[0100] , wherein (B) is a phenylalkamine or phenylalkamide of a nut oil.

[0295]

[0102] The material construct of any one of

[0100] -

[0101] , wherein the nut oil is one or more selected from the group consisting of almond oil, argan oil, avocado oil, Brazil nut oil, cashew oil, cashew nutshell liquid, groundnut oil, hazelnut oil, macademia nut oil, nutmeg oil, pecan oil, pine nut oil, pistachio oil, and walnut oil.

[0296]

[0103] The material construct of any one of

[0084] -

[0102] , wherein (B) is a phenylalkamine or phenylalkamide of a cardanol compound.

[0297]

[0104] The material construct of any one of

[0084] -

[0103] , wherein the coating composition comprises from 10 to 20 wt% of component (B).

[0298]

[0105] The material construct of any one of

[0084] -

[0104] , wherein (C) is selected from the group consisting of a solvent, a filler, a plasticizer, a stabilizer, and an other additive or a mixture thereof. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0299]

[0106] The material construct of any one of

[0084] -

[0105] , wherein the other additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a filler, a reinforcement, a chain extender, a corrosion inhibitor, an oil resin (e.g., soy oil resin), a bio-based starch, and a crosslinker.

[0300]

[0107] The material construct of any one of

[0084] -

[0106] , wherein (C) is a filler.

[0301]

[0108] The material construct of any one of

[0084] -

[0107] , wherein (C) is a bio-based filler.

[0302]

[0109] The material construct of any one of

[0084] -

[0108] , wherein (C) is a plasticizer.

[0303]

[0110] The material construct of any one of

[0084] -

[0109] , wherein (C) is a bio-based plasticizer.

[0304]

[0111] The material construct of any one of

[0084] -

[0110] , wherein (C) is a stabilizer.

[0305]

[0112] The material construct of any one of

[0084] -

[0111] , wherein the coating composition has 24 wt% to 95 wt% bio-based materials.

[0306] In the context of the present description, all publications, patent applications, patents and other references mentioned herein, if not otherwise indicated, are explicitly incorporated by reference herein in their entirety for all purposes as if fully set forth, and shall be considered part of the present disclosure in their entirety.

[0307] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In case of conflict, the present specification, including definitions, will control. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0308] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others or ordinary skill in the art to understand the embodiments disclosed herein.

[0309] Except where expressly noted, trademarks are shown in upper case.

[0310] Unless stated otherwise, all percentages, parts, ratios, etc., are by weight.

[0311] When an amount, concentration, or other value or parameter is given as a range, or a list of upper and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper and lower range limits, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the present disclosure be limited to the specific values recited when defining a range. Further, where a numerical limit or range is stated herein, the endpoints are included. Also, all values and subranges within a numerical limit or range are specifically included as if explicitly written out.

[0312] Further, unless otherwise explicitly stated to the contrary, when one or multiple ranges or lists of items are provided, this is to be understood as explicitly disclosing any single stated value or item in such range or list, and any combination thereof with any other individual value or item in the same or any other list.

[0313] When the term “about” is used, it is used to mean a certain effect or result can be obtained within a certain tolerance, and the skilled person knows how to obtain the tolerance. Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0314] When the term "about" is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to.

[0315] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0316] The transitional phrase "consisting of" excludes any element, step, or ingredient not specified in the claim, closing the claim to the inclusion of materials other than those recited except for impurities ordinarily associated therewith. When the phrase "consists of" appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0317] The transitional phrase "consisting essentially of" limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. A “consisting essentially of’ claim occupies a middle ground between closed claims that are written in a “consisting of’ format and fully open claims that are drafted in a “comprising” format. Optional additives as defined herein, at a level that is appropriate for such additives, and minor impurities are not excluded from a composition by the term “consisting essentially of’.

[0318] As used herein, an "embodiment" means that a particular feature, structure or characteristic is included in at least one or more manifestations, examples, or implementations of this invention. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art. Combinations of features of different embodiments are all meant to be Attorney Docket No. BIOB-12 / 01WO 40787 / 64 within the scope of the invention, without the need for explicitly describing every possible permutation by example. Thus, any of the claimed embodiments can be used in any combination.

[0319] Further, unless expressly stated to the contrary, “and / or” refers to an inclusive and not to an exclusive. Thus, “and / or” should be understood to mean “either or both” of the elements so conjoined, e.g., elements that are conjunctively present in some cases and disjunctively present in other cases. For example, a condition A and / or B, is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0320] The use of "a" or "an" to describe the various elements and components herein is merely for convenience and to give a general sense of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements.

[0321] The above written description of the invention provides a manner and process of making and using it such that any person skilled in this art is enabled to make and use the same, this enablement being provided in particular for the subject matter of the appended claims, which make up a part of the original description.

[0322] As used herein, the phrases “selected from the group consisting of,” “chosen from,” and the like include mixtures of the specified materials.

[0323] The above written description of the invention provides a manner and process of making and using it such that any person skilled in this art is enabled to make and use the Attorney Docket No. BIOB-12 / 01WO 40787 / 64 same, this enablement being provided in particular for the subject matter of the appended claims, which make up a part of the original description.

[0324] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.

[0325] The above description is presented to enable a person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, this invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.

[0326] Having generally described this invention, a further understanding can be obtained by reference to certain specific examples, which are provided herein for purposes of illustration only, and are not intended to be limiting unless otherwise specified.

[0327] EXAMPLES

[0328] Example 1 -

[0329] A bio-based epoxy is prepared with 40% epoxidized soybean oil as the resin, 15% modified cashew nutshell liquid as the hardener, and 45% water.

[0330] Example 2 - Attorney Docket No. BIOB-12 / 01WO 40787 / 64

[0331] A bio-based epoxy is formulated with 35% epoxidized linseed oil as the resin, 10% modified almond oil as the hardener, 15% wood flour as a filler, and 40% water.

[0332] Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.

Claims

Attorney Docket No. BIOB-12 / 01WO 40787 / 64CLAIMSWhat we claim is1. A coating composition comprising:(A) a water-based epoxy resin;(B) bio-based hardener; and(C) one or more additives.

2. The coating composition of claim 1, wherein (C) is a solvent that is free of or has low volatile organic compounds content.

3. The coating composition of claim 2, wherein the solvent is water.

4. The coating composition of claim 1, wherein (A) is selected from the group consisting of an epoxidized oil, an epoxidized natural rubber, and a modified plant-based starch with an epoxy functionality.

5. The coating composition of claim 1, wherein (A) is an epoxidized soybean oil or an epoxidized linseed oil.

6. The coating composition of claim 1, wherein (B) is a nut oil modified to contain an amine functionality.

7. The coating composition of claim 6, wherein the nut oil is one or more selected from the group consisting of almond oil, argan oil, avocado oil, Brazil nut oil, cashew oil,Attorney Docket No. BIOB-12 / 01WO 40787 / 64 cashew nutshell liquid, groundnut oil, hazelnut oil, macademia nut oil, nutmeg oil, pecan oil, pine nut oil, pistachio oil, and walnut oil.

8. The coating composition of claim 1, wherein (B) is a phenylalkamine or phenylalkamide of a cardanol compound.

9. The coating composition of claim 1, wherein the coating composition comprises from 30 to 75 wt% of component (A) and from 10 to 20 wt% of component (B).

10. The coating composition of claim 1, wherein (C) is selected from the group consisting of a solvent, a filler, a plasticizer, a stabilizer, and an other additive or a mixture thereof.

11. The coating composition of claim 1, wherein the other additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a filler, a reinforcement, a chain extender, a corrosion inhibitor, an oil resin, a bio-based starch, and a crosslinker.

12. The coating composition of claim 1, wherein the coating composition has 24 wt% to 95 wt% bio-based materials.

13. A method of making a coating composition, comprisingAttorney Docket No. BIOB-12 / 01WO 40787 / 64 stirring, shaking, or agitating (A) a water-based epoxy resin, (B) a bio-based hardener, and (C) one or more additives for a time and under conditions sufficient to blend the (A) the water-based epoxy resin, (B) the bio-based hardener, and (C) the one or more additives to substantial homogeneity thus forming the coating composition.

14. The method of claim 13, wherein (C) comprises a solvent that is free of or has low volatile organic compounds content.

15. The method of claim 14, wherein the solvent is water.

16. The method of claim 13, wherein (A) is selected from the group consisting of an epoxidized oil, an epoxidized natural rubber, and a modified plant-based starch with an epoxy functionality.

17. The method of claim 13, wherein (B) is a nut oil modified to contain an amine functionality.

18. The method of claim 13, wherein (C) is selected from the group consisting of a solvent, a filler, a plasticizer, a stabilizer, and an other additive or a mixture thereof.

19. A coated material wherein a surface of a material has a coating of a cured product of a coating composition comprising (A) from 30 to 75 wt% of a water-based epoxy resin, (B) from 10 to 20 wt% of a bio-based hardener, and (C) one or more additives, wherein the coating has at least 24 wt% of bio-based components based on the total solids content of the coating and wherein the total thickness of the coating ranges from 1 to 500 mils.Attorney Docket No. BIOB-12 / 01WO 40787 / 6420. The material construct of claim 19, wherein the material is selected from the group consisting of asphalt, ceramic, glass, concrete, wood, metal, galvanized steel, ungalvanized steel, tile, paper packaging, composites, textile and plastic.

Images