Coating comprising cationically cured material

Abstract

The present application relates to a coating composition comprising at least one anhydrous hydrophobic material and at least one cationically curable material, wherein the at least one anhydrous hydrophobic material and the at least one cationically curable material are substantially miscible. Methods of making the coating compositions and articles including the coating compositions described herein are also described.

Description

Technical Field

[0001] This disclosure relates throughout to coating compositions comprising at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible. Methods for preparing the coating and articles comprising the coating are also disclosed. Background Technology

[0002] Recently, water-based and solvent-based transparent coatings and colorants have been used in many applications, including but not limited to general industrial, building materials, household and business, wood, composite materials and other coatable goods.

[0003] Many of these coatings are used in external applications and are cured via ultraviolet (UV) curing. UV curing, also known as free radical UV curing, is a standard curing method used in the coatings industry. Although this UV curing process can occur under sunlight, some parts of the coating may not cure completely, such as shaded areas or areas with only indirect light. Furthermore, external conditions can change frequently, which may delay or disrupt the free radical UV curing process. Additionally, many internal coatings can be cured with UV light, but a lack of proper UV curing equipment may prevent such coatings from curing completely. These internal coatings may also not be exposed to sufficient UV light sources, such as windows, thus reducing their ability to cure completely. Additionally, oxygen inhibition in the typical free radical UV curing process can lead to poor surface curing. Specifically, the free radical polymerization of free radical UV-cured coatings is susceptible to oxygen inhibition because oxygen may come into contact with the coating surface and then terminate the reaction. This can result in insufficient curing on the surface or a very thin film that prevents further curing. Furthermore, other issues may arise for customers using free radical UV-cured products, such as toxicity, skin irritation, and odor.

[0004] Alternatively, cationic curing can be used instead of free radical UV curing. Cationic curing chemistry is UV-initiated cationic polymerization. Although exposing the coating to sunlight can initiate the cationic curable process, continuous exposure to UV light is not required for complete curing. Cationic curing is also not inhibited by oxygen, allowing curing to occur after it has been UV-initiated. Although cationic curing is used in inks and 3D printing applications, curing conditions must be strictly controlled, otherwise they may not cure adequately. For example, cationic curing may be terminated, delayed, or destroyed due to the presence of moisture, which can often occur in external applications or other applications where moisture cannot be controlled. These disadvantages limit the use of cationic curing in coatings, especially for external products and where curing conditions are uncontrollable.

[0005] Additionally, consumers must choose between solvent-based and water-based coatings. Typically, these solvent-based coatings are oil-based coatings that cure through oxidative cross-linking. Oil-based coatings are generally easier to apply to substrates such as wood than water-based coatings. Oil-based coatings penetrate the wood, reducing caking and future peeling. However, oil-based coatings take longer to dry than water-based coatings and contain higher VOCs. Furthermore, they are more likely to serve as a food source for mold, mildew, and algae. For example, long-oil alkyd resins have been used in high-solids coatings, especially wood stains. However, their performance is affected by slow drying times and tackiness. To overcome these challenges, water-dilutable alkyd resin technologies have been developed to achieve low VOC targets; however, the high polarity of alkyd resins reduces their performance characteristics, including weather resistance.

[0006] Alternatively, water-based coatings typically offer improved UV resistance and color retention. While water-based coatings offer better drying times, mold resistance, mildew resistance, and algae resistance than oil-based coatings, they are more difficult to apply. Because they are less likely to penetrate substrates such as wood, they are also more prone to peeling if over-applied.

[0007] Consumers are increasingly demanding specific performance characteristics from coatings, especially exterior wood coatings, requiring consistent curing and minimal impact from varying external conditions. They are constantly seeking coatings that exhibit these properties (such as weather resistance, abrasion resistance, adhesion, application ease, curing time, and resistance to mold, mildew, and algae) without sacrificing other properties. Given these challenges faced by many conventional coatings, there remains a need for improved coatings that offer weather resistance, abrasion resistance, adhesion, and other enhanced properties, as well as additional post-curing advantages. Summary of the Invention

[0008] The embodiments described herein are not intended to be exhaustive or limiting of what is provided in the claimed subject matter and disclosed in the specific embodiments. Rather, the embodiments were chosen and described so that others skilled in the art can recognize and understand the principles and practices provided in the claimed subject matter.

[0009] A coating and a method for preparing the same are shown and described. The coating composition may comprise at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible.

[0010] A method for preparing a coating composition is also described, the coating composition comprising at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible. An article containing a coating composition is also described, the coating composition comprising at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible.

[0011] To achieve the foregoing and related objectives, certain exemplary aspects and implementations are described below. These representations may take place in some of a variety of ways, including one or more aspects. Other aspects, advantages, and novel features of this disclosure will become apparent upon consideration from the following detailed description. Attached Figure Description

[0012] Preferred embodiments of the invention will be described in detail in the specification and illustrated in the accompanying drawings, which form a part of the specification, wherein: Figure 1 A panel coated with a conventional curing paint and a paint composition containing a cationic curing material as described herein is shown, which has been subjected to outdoor weathering conditions.

[0013] Figure 2 A panel coated with a conventional curing paint and a paint composition containing a cationic curing material as described herein is shown, which has been subjected to outdoor weathering conditions.

[0014] Figure 3 The paper shows a comparison of water resistance between a wood panel coated with and cured with the coating composition containing cationic curing material described herein and an untreated panel. Detailed Implementation

[0015] Aspects of the content described herein are disclosed in the following description relating to specific embodiments. Alternative embodiments may be designed without departing from the scope of the content described herein. Furthermore, well-known embodiments of the content described herein may be omitted in detail or omitted so as not to obscure the relevant details of the content described herein. Further, for ease of understanding this specification, several terms used herein are discussed below.

[0016] As used herein, the term "exemplary" means "serving as an example, instance, or illustration." The embodiments described herein are not restrictive but merely exemplary. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, the term "implementation" does not require all embodiments to include the features, advantages, or modes of operation discussed.

[0017] This disclosure relates generally to coatings that offer advantageous improvements over current coatings. It has been found that using specific coating compositions—comprising at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible—can surprisingly produce preferred performance characteristics when used in coatings, namely improved weather resistance, abrasion resistance, adhesion, drying time and tack, applyability, curing time, reduced odor, lower toxicity, reduced skin irritation, and resistance to mold, mildew, and algae, while also having reduced VOCs without sacrificing other performance characteristics and other advantages. In particular, coating compositions comprising at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible, can have improved performance superior to typical UV-cured or cationic-cured coatings. Furthermore, the coating compositions described herein comprise at least one anhydrous hydrophobic material and at least one cationic curing material; wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible, and can exhibit certain improved properties superior to many solvent-based or water-based coatings and conventional coatings cured using free radical UV. By combining at least one anhydrous hydrophobic material with at least one cationic curing material, many problems of typical cationic curing can be substantially overcome.

[0018] While not bound by theory, the ability of cationic curing and chain transfer with hydroxyl groups (such as those in cellulose and lignin of wood) provides a method for covalently bonding coating compositions to substrates and providing improved adhesion and properties. Applications using both UV curing and cationic curing can be formulated with photoinitiators that decompose under normal sunlight, allowing for environmental initiation of the reaction. However, photoinitiators used for cationic curing do not decompose to form free radicals, but rather strong Brønsted acids. The term "anhydrous hydrophobic" refers to materials used in coating compositions that are substantially free of water, preferably in which water is present at a content of less than or equal to 2% by weight relative to the total weight of the composition and substantially does not interact with water. "Cationic" describes the base portion of the initiator conjugated with the Brønsted acid and refers to the portion of the molecule that absorbs radiation to initiate curing. Free radicals generated by free radical UV-curing photoinitiators can have relatively short half-lives (typically several seconds), therefore the curing mechanism requires constant UV exposure to continuously generate new free radicals to drive curing to completion. Unlike free radicals, Brønsted acids in cationic curing have a longer half-life, typically ranging from hours to days, allowing them to persist in the coating and drive curing. Therefore, UV cationic curing chemistry can be used for exterior coating products under outdoor conditions, while free radical UV-cured products will be prevented from fully curing in areas without sufficient UV sources, such as shaded and dark areas. UV cationic curing also provides more consistent and uniform curing than UV free radical curing because the product is not affected by shadows from clouds, trees, and other vegetation or structures throughout the day. Furthermore, Brønsted acids can catalyze cationic curing of resins through ring-opening reactions, potentially leading to lower shrinkage and increased adhesion of the coating. Table 1 below further highlights the benefits of using cationic curing over free radical UV curing.

[0019] Table I: Radiation Curing Chemistry - Free Radicals vs. Cationic feature free radicals cation Curing speed high Moderate to high Trigger Light Photothermal Oxygen sensitivity yes no Shrinkage big Negligible Adhesion Medium to good Excellent Post-curing Limited effect Strong effect Chemical resistance good Medium to good Moisture resistance no yes Acid / base sensitivity no yes From Verschueren, Kris, and Kaur, Balwant, “Cycloaliphatic Epoxide Resins for Cationic UV-Cure” (RADTECH ASIA'99. Conference Proceedings of the Conference on Radiation Curing: Technologies for the Next Millennium) The UV cationic curing reaction shown below illustrates the polymerization process in which a ring-opening reaction occurs.

[0020]

[0021]

[0022] The coating compositions described herein protect the cationic reaction mechanism from water or moisture that may be present in certain environments, particularly external environments, by creating an anhydrous or substantially anhydrous environment, thus providing coating compositions that do not inhibit curing by oxygen or water. Because they are also hydrophobic, exposure to water is also reduced.

[0023] The coating composition described herein is a UV cationic curable coating. The coating composition cures when UV light initiates a cationic curing reaction but is not required to sustain it. Furthermore, in some embodiments, at least one anhydrous hydrophobic material and at least one cationic curing material may be copolymerized with each other. Additionally, besides UV and cationic curing, at least one anhydrous hydrophobic material may be cured by oxidative drying, or cured separately from these curing methods by oxidative drying.

[0024] In many embodiments, the coating compositions described herein comprise at least one anhydrous hydrophobic material and at least one cationic curing material; wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible. If the at least one anhydrous hydrophobic material and the at least one cationic curing material are not completely miscible or substantially miscible, the anhydrous hydrophobic material and the cationic curing material can be adjusted to ensure compatibility such that they are substantially miscible. Compatibility can be ensured through the selection of materials in the coating composition.

[0025] Furthermore, in many embodiments, at least one anhydrous hydrophobic material in the coating composition described herein comprises at least one alkyd resin, at least one solution polymer, at least one solvent-based acrylic, at least one urethane, at least one oil, at least one solvent, or a combination thereof. In many embodiments, at least one anhydrous hydrophobic material is substantially miscible in solvent-based coatings. In some embodiments, at least one anhydrous hydrophobic material is substantially miscible in water-based coatings. In many embodiments, at least one anhydrous hydrophobic material in the coating composition can at least partially penetrate into the substrate. Without being bound by theory, at least one anhydrous hydrophobic material can create an anhydrous hydrophobic environment that protects the cationic curing material in the coating composition from water-induced reaction inhibition. By inhibiting or preventing reaction with water, the coating composition described herein can cure under external conditions or under conditions where humidity cannot be controlled.

[0026] In many embodiments, at least one alkyd resin may comprise various oil lengths. In some embodiments, at least one alkyd resin may be derived from a bio-based source, such as vegetable oil.

[0027] In many embodiments, at least one solution polymer comprises at least one: acrylic polyol, acrylic acid, alkyd resin, oil-modified urethane, acrylic acid-modified alkyd resin, or combinations thereof. Typical solvents used for solution polymerization may include, but are not limited to, water, ethanol, mixtures of water and ethanol, diethyl ether, benzyl alcohol, and benzyl alcohol. The solvents used in solution polymerization can be removed during the processing of the solution polymer.

[0028] In some embodiments, the acrylic portion of at least one solvent-based acrylic acid may include an alkyl methacrylate and a vinyl monomer, such as, but not limited to, methyl methacrylate, ethyl methacrylate, propyl methacrylate, n- / iso / tert-butyl methacrylate, 2-ethylhexyl methacrylate, lauryl methacrylate, stearyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, glycidyl methacrylate, 4-hydroxybutyl acrylate glycidyl ether, 2-(acetylacetoxy)ethyl methacrylate, lauryl methacrylate, stearyl methacrylate, cyclohexyl methacrylate, diacetone acrylamide, acrylamide, methacrylamide, hydroxymethyl (meth)acrylamide, styrene, α-methylstyrene, vinyltoluene, vinyl acetate, vinyl propionate, allyl methacrylate, or combinations thereof. In some embodiments, the alkyl methacrylate polymer may be those prepared from C12 to C22 alkyl methacrylates. Some preferred monomers include styrene, methyl methacrylate, methacrylic acid, hydroxyethyl acrylate, acetyl methacrylate, butyl acrylate, butyl methacrylate, or combinations thereof. Others are also contemplated.

[0029] In many embodiments, at least one oil is a conjugated oil. In some embodiments, the conjugated oil includes linseed oil, castor oil, soybean oil, sunflower oil, safflower oil, tall oil, nahar oil, tobacco seed oil, coconut oil, rubber seed oil, Kalanja oil, Resclero oil, tung oil, or combinations thereof. Other oils are also contemplated.

[0030] In many embodiments, at least one solvent comprises a non-drying oil. In some embodiments, at least one solvent comprises mineral oil, butyl acetate, n-butyl propionate, diethylene glycol monoethyl acetate, ethylene glycol monobutyl ether acetate, ethyl 3-ethoxypropionate, ethyl acetate, 2-ethylhexyl acetate, isobutyl acetate, isobutyl isobutyrate, isopropyl acetate, methyl acetate, methyl n-pentyl ketone, methyl isopentyl ketone, methyl propyl ketone, propylene glycol monomethyl ether acetate, propyl acetate, n-propyl propionate, or combinations thereof. Other solvents are also contemplated.

[0031] In many embodiments, at least one cationic curing material comprises at least one cationic photoinitiator, at least one acid catalyst, or a combination thereof. At least one cationic curing material can be initiated by UV. However, the use of at least one anhydrous hydrophobic material can significantly reduce or prevent the termination of the cationic reaction by water. In many embodiments, the coating compositions described herein are substantially immiscible with water. In one embodiment, the coating composition described herein is completely immiscible with water.

[0032] In some embodiments, the coating compositions described herein comprise at least one cationic photoinitiator. This cationic photoinitiator is UV-curable. In one embodiment, the at least one cationic photoinitiator comprises triphenylsulfonium, diaryliodonium, diazonium salt, diaryliodonium salt, ferroceneium salt, triarylsulfonium salt, alkylsulfonium salt, ferroaryl salt, sulfonyloxyketone, triarylsiloxysiloxane, or combinations thereof. In other embodiments, the at least one cationic photoinitiator comprises various other metallocene compounds. In yet another embodiment, the at least one cationic photoinitiator comprises bis-(4-tert-butylphenyl)-iodonium hexafluorophosphate. In still another embodiment, the at least one cationic photoinitiator may be sensitized with at least one UV photoinitiator to initiate UV curing and facilitate the UV cationic curing reaction. Other cationic photoinitiators are also contemplated.

[0033] In some embodiments, the coating compositions described herein comprise at least one acid catalyst. In many embodiments, the at least one acid catalyst includes sulfuric acid, sulfonic acid, hydrochloric acid, organic sulfonic acid, ferric sulfate, hydrofluoric acid, phosphoric acid, toluenesulfonic acid, polystyrene sulfonate, heteropoly acid, zeolite, acetic acid, or combinations thereof. Other acid catalysts are also contemplated. In some embodiments, at least one acid catalyst may be used to provide a 2K system for the coating composition.

[0034] Furthermore, as used herein, various additives refer to components or other raw materials of a general class that can be added to the compositions herein to promote various properties. In many embodiments, the coating compositions described herein also comprise at least one polymer, at least one reactive diluent, at least one non-reactive diluent, at least one solvent, at least one drier, at least one colorant, at least one pigment, at least one surfactant, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildew inhibitor, at least one thickener, or combinations thereof. Other additives may include, but are not limited to, polymers or polymer dispersions, leveling agents, antisettling agents, pH buffers, corrosion inhibitors, driers, antiskinning agents, anti-cratering agents, anti-sagging agents, heat stabilizers, UV absorbers / inhibitors, HALS (hindered amine light stabilizers), antioxidants, wetting agents, flow agents, etc., and various combinations thereof required for a particular application. Other additives are also contemplated.

[0035] In one embodiment, the coating composition described herein further comprises a UV radical material. The UV radical material in the coating composition can provide cationic / radical UV hybrid curing.

[0036] In other embodiments, the coating compositions described herein further comprise at least one epoxy resin. The epoxy resin can be reacted in a UV cationic curing process. Using epoxy resin with at least one alkyd resin, at least one solution polymer, at least one solvent-based acrylic, at least one urethane, or combinations thereof can provide certain advantages to the mixed system. These advantages may include a slower curing time than at least one alkyd resin, at least one solution polymer, at least one solvent-based acrylic, at least one urethane, or combinations thereof, if such a slower curing time is desired. In some embodiments, at least one epoxy resin may be derived from a bio-based source, such as soybean oil. Furthermore, in many embodiments, the coating compositions described herein that also comprise epoxy resin may comprise at least one polyol, including but not limited to acrylic polyols, polyester polyols, or combinations thereof, because the cationic curing mechanism involves chain transfer with hydroxyl groups. The addition of at least one polyol can allow adjustment of the film hardness of the coating compositions described herein.

[0037] In some embodiments, at least one anhydrous hydrophobic material is part of an interpenetrating polymer network (IPN). In many embodiments, having an IPN can lead to additional performance improvements. In one embodiment, the IPN can be provided by radical polymerization (such as in radical UV curing), oxidative crosslinking, or a combination thereof. Other polymerization and crosslinking mechanisms are also considered.

[0038] In some embodiments, the coating compositions described herein further comprise at least one bifunctional material. This bifunctional material is intended for curing via a mechanism different from that of IPN. In some embodiments, the at least one bifunctional material comprises: 1) a cyclic ether or hydroxyl group with an unsaturated olefin, 2) a cyclic ether with an acrylate, or 3) a combination thereof. In one embodiment, the bifunctional material can be provided by free radical polymerization (e.g., in free radical UV curing), oxidative crosslinking, or a combination thereof. For example, both free radical polymerization of acrylates (e.g., in free radical UV curing) and oxidative crosslinking of alkyd resins can be used to provide a bifunctional material. Other polymerization and crosslinking mechanisms are also considered.

[0039] In many embodiments, the coating compositions described herein provide coating formulations with reduced VOCs. In many embodiments, the VOCs of the coating compositions described herein are 500 g / L or less, as measured by ASTM D3960. In some embodiments, the coating compositions described herein have volatile organic compounds (VOCs) of less than 250 g / L, as measured by ASTM D3960. In other embodiments, the coating compositions described herein may have volatile organic compounds (VOCs) of less than 450 g / L, less than 400 g / L, less than 350 g / L, less than 300 g / L, less than 275 g / L, less than 225 g / L, less than 200 g / L, less than 175 g / L, less than 150 g / L, less than 125 g / L, less than 100 g / L, less than 75 g / L, less than 50 g / L, and less than 25 g / L, as measured by ASTM D3960. Lower and higher levels of VOCs are also considered.

[0040] In many embodiments, the coating compositions described herein have a volatile organic compound (VOC) content of less than about 250 g / L according to EPA M24. In other embodiments, the coating compositions described herein may have VOCs of less than 225 g / L, less than 200 g / L, less than 175 g / L, less than 150 g / L, less than 125 g / L, less than 100 g / L, less than 75 g / L, less than 50 g / L, and less than 25 g / L as measured by EPA M24. Lower and higher levels of VOCs are also considered.

[0041] In many embodiments, the coating compositions described herein can provide formulations of coatings containing higher solids.

[0042] In many embodiments, the coating composition described herein is a wood stain. In many embodiments, the coating composition is a clear coat, a translucent coat, a semi-solid coat, or a solid colored coat. In one embodiment, the coating composition described herein is a translucent or lightly tinted wood stain. In one embodiment, the coating composition described herein is a translucent wood stain. In one embodiment, the coating composition described herein is a solid-color wood stain. In another embodiment, the coating composition described herein is a clear coat. In other embodiments, the coating composition described herein is a primer. In yet another embodiment, the coating composition described herein is a colored paint. In some other embodiments, the coating composition described herein is a topcoat.

[0043] In many embodiments, the coating compositions described herein are one-component systems. In other embodiments, the one-component systems described herein are two-component systems.

[0044] This article also describes a method for preparing the coating described herein, the coating comprising at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible.

[0045] A method for at least partially applying a coating composition comprising at least one anhydrous hydrophobic material and at least one cationic curing material is also described, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible with at least one substrate. In many embodiments, the at least one substrate is wood, metal, glass, plastic, paper, leather, fabric, ceramic, concrete, composite material, or a combination thereof. In one embodiment, the at least one substrate is a pre-coated substrate. In many embodiments, at least partial application of the coating can be achieved by brushing, rolling, spraying (air atomization, airless spraying, high-volume low-pressure (HVLP) spraying, and electrostatic spraying), padding, dip coating, roller coating, spin coating, flow coating, curtain coating, centrifugal coating, continuous coating, and automated deposition. Other application methods are also contemplated.

[0046] In many embodiments, articles comprising the coating composition described herein are also disclosed. The article comprises a coating composition containing at least one anhydrous hydrophobic material and at least one cationic curing material, wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible. In some embodiments, an article may comprise: 1) a substrate having at least one surface; and 2) the coating composition described herein. In some embodiments, the substrate is wood, metal, glass, plastic, paper, leather, fabric, ceramic, concrete, composite material, or a combination thereof. In other embodiments, the substrate is a previously coated substrate. The previously coated substrate may be a substrate covered with an aqueous or solvent-based coating. In many embodiments, the previously coated substrate comprises a coating. In yet another embodiment, the previously coated substrate comprises at least one additional coating. In many embodiments, the at least one additional coating may comprise a solvent-based or aqueous coating. In one embodiment, the at least one additional coating may be different from the coating composition described herein. In another embodiment, the at least one additional coating may be the same as the coating composition described herein.

[0047] Figure 1 Photographs of panels coated with conventional UV-curable coatings and coating compositions containing cationic curing materials as described herein are shown in detail. Figure 1 The panels shown were subjected to outdoor weathering conditions with multiple freeze-thaw cycles over a year in northeastern Ohio. The photographs clearly distinguish the conventional UV-cured solvent-based paint (shown as B) from the paint composition described herein, which contains a cationic curing material (shown as A), after one year. Although they had similar and indistinguishable appearances before outdoor weathering, after one year of outdoor exposure, the cationic paint composition now clearly shows less wear and color inconsistency than the conventional UV-cured paint.

[0048] Figure 2 Photographs of panels coated with conventional alkyd-based external wood stains and the coating composition containing cationic curing materials described herein are also shown in detail. Figure 2The panels shown were subjected to outdoor weathering conditions with multiple freeze-thaw cycles over a year in northeastern Ohio. The photographs show a conventional alkyd-based exterior wood stain (shown as D) and the coating composition described herein, containing a cationic curing material, before outdoor weathering (shown as C). However, they are distinguishable after one year of outdoor exposure. Although they had similar and indistinguishable appearances before outdoor weathering, after one year of outdoor exposure, the cationic coating composition (shown as E) now clearly shows less wear and color inconsistency than the conventional alkyd-based exterior wood stain (shown as F). Furthermore, the conventional alkyd-based exterior wood stain (shown as F) shows signs of fading and peeling compared to the cationic coating composition (shown as E). The conventional alkyd-based exterior wood stain (shown as F) exhibits a significant color change, becoming grayish, compared to its pre-exposure appearance (shown as D).

[0049] Figure 3 The water resistance of a wood panel (shown as G) coated with the coating composition comprising a cationic curing agent described herein is provided compared to an untreated wood substrate (shown as H). The coating composition comprising a cationic curing material described herein provides penetration into the wood substrate as well as water resistance, while water can penetrate into the untreated wood substrate (shown as H).

[0050] Implementation Plan The following implementation schemes are envisioned. All combinations of features and implementation schemes are envisioned.

[0051] Implementation Scheme 1: A coating composition comprising: at least one anhydrous hydrophobic material; and at least one cationic curing material; wherein the at least one anhydrous hydrophobic material and the at least one cationic curing material are substantially miscible.

[0052] Implementation Scheme 2: According to the implementation scheme of Implementation Scheme 1, the at least one anhydrous hydrophobic material includes at least one alkyd resin, at least one solution polymer, at least one solvent-based acrylic acid, at least one urethane, at least one oil, at least one solvent, or a combination thereof.

[0053] Implementation Scheme 3: According to the implementation scheme of Implementation Scheme 2, the at least one solution polymer includes at least one: acrylic polyol, acrylic acid, alkyd resin, oil-modified urethane, acrylic acid-modified alkyd resin, or a combination thereof.

[0054] Implementation Scheme 4: According to the implementation scheme described in Implementation Scheme 2, the at least one oil is a conjugate oil.

[0055] Implementation Scheme 5: According to the implementation scheme described in Implementation Scheme 4, the conjugate oil includes linseed oil, castor oil, soybean oil, sunflower oil, safflower oil, tall oil, neroli oil, tobacco seed oil, coconut oil, rubber seed oil, Kalanja oil, Resclero oil, tung oil, or combinations thereof.

[0056] Implementation Scheme 6: According to the implementation scheme described in Implementation Scheme 2, wherein the at least one solvent comprises mineral oil, butyl acetate, n-butyl propionate, diethylene glycol monoethyl acetate, ethylene glycol monobutyl ether acetate, ethyl 3-ethoxypropionate, ethyl acetate, 2-ethylhexyl acetate, isobutyl acetate, isobutyl isobutyrate, isopropyl acetate, methyl acetate, methyl n-pentyl ketone, methyl isopentyl ketone, methyl propyl ketone, propylene glycol monomethyl ether acetate, propyl acetate, n-propyl propionate, or combinations thereof.

[0057] Implementation Scheme 7: According to any one of Implementation Schemes 1 to 6, the at least one cationic curing material comprises at least one cationic photoinitiator, at least one acid catalyst, or a combination thereof.

[0058] Implementation Scheme 8: According to any one of Implementation Schemes 1 to 7, wherein the coating composition is substantially immiscible with water.

[0059] Implementation Scheme 9: According to any one of Implementation Schemes 1 to 8, the coating composition further comprises at least one polymer, at least one reactive diluent, at least one non-reactive diluent, at least one solvent, at least one drying agent, at least one colorant, at least one pigment, at least one surfactant, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildew inhibitor, at least one thickener, or a combination thereof.

[0060] Implementation Scheme 10: According to any one of Implementation Schemes 1 to 9, wherein the at least one anhydrous hydrophobic material is part of an interpenetrating polymer network (IPN).

[0061] Implementation Scheme 11: According to any one of Implementation Schemes 1 to 9, the implementation scheme further comprises at least one bifunctional material.

[0062] Implementation Scheme 12: According to the implementation scheme of Implementation Scheme 11, at least one bifunctional material comprises a cyclic ether or hydroxyl group with an unsaturated olefin, a cyclic ether with an acrylate, or a combination thereof.

[0063] Implementation Scheme 13: According to any one of Implementation Schemes 1 to 12, wherein the coating composition is a wood staining agent.

[0064] Implementation Scheme 14: According to any one of Implementation Schemes 1 to 12, wherein the coating composition is a transparent coating, a translucent coating, a semi-solid coating, or a solid colored coating.

[0065] Implementation Scheme 15: According to any one of Implementation Schemes 1 to 14, wherein the coating composition is a one-component system.

[0066] Implementation Scheme 16: According to any one of Implementation Schemes 1 to 14, wherein the coating composition is a two-component system.

[0067] Implementation Scheme 17: A method for preparing a coating composition according to any one of Implementation Schemes 1 to 16.

[0068] Embodiment 18: A method of applying at least partially the coating composition of any one of Embodiments 1 to 16 to at least one substrate.

[0069] Implementation Scheme 19: According to the implementation scheme of Implementation Scheme 18, at least one substrate is wood, metal, glass, plastic, paper, leather, fabric, ceramic, concrete, composite material or a combination thereof.

[0070] Implementation Scheme 20: According to the implementation scheme of Implementation Scheme 18, at least one substrate is a previously coated substrate.

[0071] Implementation Scheme 21: An article comprising a coating composition according to any one of Implementation Schemes 1 to 16.

[0072] The foregoing description includes examples of the claimed subject matter. All details, as well as any modifications described in conjunction with the background and specific embodiments, will be apparent to those skilled in the art within the substance and scope of the claimed subject matter. Furthermore, it should be understood that aspects of the claimed subject matter, as well as portions of the various embodiments and features described below and / or in the appended claims, can be combined or interchanged, in whole or in part. In the foregoing description of the various embodiments, those embodiments referenced to another embodiment may be suitably combined with other embodiments, as will be recognized by those skilled in the art. Moreover, those skilled in the art will recognize that the foregoing description is presented as an example only and is not intended to limit the claimed subject matter, recognizing that many other combinations and arrangements of the claimed subject matter are possible. Of course, it is impossible to describe every conceivable combination of components or methods for the purpose of describing the claimed subject matter, but these will be recognized by those skilled in the art. Therefore, the claimed subject matter is intended to cover all such changes, modifications, and variations that fall within the substance and scope of the appended claims. Furthermore, with regard to the use of the term "comprising" in the specific embodiments or claims, such a term is intended to be inclusive in a manner similar to how the term "including" is interpreted as "comprising" when used as a transitional word in a claim.

Claims

1. A coating composition comprising: At least one anhydrous hydrophobic material; and At least one cationic curing material; At least one anhydrous hydrophobic material and at least one cationic curing material are substantially miscible.

2. The coating composition according to claim 1, wherein at least one anhydrous hydrophobic material comprises at least one alkyd resin, at least one solution polymer, at least one solvent-based acrylic acid, at least one urethane, at least one oil, at least one solvent, or a combination thereof.

3. The coating composition according to claim 2, wherein the at least one solution polymer comprises at least one: acrylic polyol, acrylic acid, alkyd resin, oil-modified urethane, acrylic acid-modified alkyd resin, or a combination thereof.

4. The coating composition according to claim 2, wherein the at least one oil is a conjugated oil.

5. The coating composition according to claim 4, wherein the conjugated oil comprises linseed oil, castor oil, soybean oil, sunflower oil, safflower oil, tall oil, neroli oil, tobacco seed oil, coconut oil, rubber seed oil, Kalanja oil, Resclero oil, tung oil, or combinations thereof.

6. The coating composition according to claim 2, wherein the at least one solvent comprises mineral oil, butyl acetate, n-butyl propionate, diethylene glycol monoethyl acetate, ethylene glycol monobutyl ether acetate, ethyl 3-ethoxypropionate, ethyl acetate, 2-ethylhexyl acetate, isobutyl acetate, isobutyl isobutyrate, isopropyl acetate, methyl acetate, methyl n-pentyl ketone, methyl isopentyl ketone, methyl propyl ketone, propylene glycol monomethyl ether acetate, propyl acetate, n-propyl propionate, or combinations thereof.

7. The coating composition according to any one of claims 1 to 6, wherein the at least one cationic curing material comprises at least one cationic photoinitiator, at least one acid catalyst, or a combination thereof.

8. The coating composition according to any one of claims 1 to 7, wherein the coating composition is substantially immiscible with water.

9. The coating composition according to any one of claims 1 to 8, wherein the coating composition further comprises at least one polymer, at least one reactive diluent, at least one non-reactive diluent, at least one solvent, at least one drying agent, at least one colorant, at least one pigment, at least one surfactant, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildew inhibitor, at least one thickener, or combinations thereof.

10. The coating composition according to any one of claims 1 to 9, wherein the at least one anhydrous hydrophobic material is part of an interpenetrating polymer network (IPN).

11. The coating composition according to any one of claims 1 to 9, wherein the coating composition further comprises at least one bifunctional material.

12. The coating composition according to claim 11, wherein at least one bifunctional material comprises a cyclic ether or hydroxyl group with an unsaturated olefin, a cyclic ether with an acrylate, or a combination thereof.

13. The coating composition according to any one of claims 1 to 12, wherein the coating composition is a wood staining agent.

14. The coating composition according to any one of claims 1 to 13, wherein the coating composition is a transparent coating, a translucent coating, a semi-solid coating, or a solid colored coating.

15. The coating composition according to any one of claims 1 to 14, wherein the coating composition is a one-component system.

16. The coating composition according to any one of claims 1 to 14, wherein the coating composition is a two-component system.

17. A method for preparing a coating composition according to any one of claims 1 to 16.

18. A method for applying at least partially a coating composition according to any one of claims 1 to 16 to at least one substrate.

19. The method of claim 18, wherein at least one substrate is wood, metal, glass, plastic, paper, leather, fabric, ceramic, concrete, composite material, or a combination thereof.

20. The method of claim 18, wherein at least one substrate is a previously coated substrate.

21. An article comprising the coating composition according to any one of claims 1 to 16.

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