Marine Coatings to Reduce Cavitation
Patent Information
- Application Number
- JP2023575614
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2021-06-10
- Filing Date
- 2022-06-10
- Publication Date
- 2025-06-17
AI Technical Summary
Existing marine vessel coatings do not effectively reduce underwater radiated noise (URN) and cavitation, and are prone to corrosion and wear, lacking sufficient sound-dampening, cavitation resistance, and durability in humid environments.
A composition comprising solvent-based monomers, diluents, adhesion promoters, and ceramic performance additives, including hollow and solid ceramic spheres, to form coatings that enhance sound deadening, hardness, and corrosion resistance.
The coatings provide significant reduction in underwater noise emissions, improved hardness and scratch resistance, and enhanced durability, addressing environmental and mechanical challenges faced by marine vessels.
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Abstract
Description
[Technical field]
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 209,278, filed June 10, 2021, the entire contents of which are incorporated herein by reference.
[0002] The present disclosure relates generally to coatings for use in wet environments. [Background technology]
[0003] The following paragraphs are not an admission that what is described therein is prior art or part of the knowledge of those skilled in the art.
[0004] Underwater radiated noise (URN) generally refers to underwater noise radiated from marine vessels such as container or tanker ships. Typical sources of URN include mechanical noise, propeller noise, and hydrodynamic noise from marine vessels. URN includes sounds radiated at frequencies below 100 Hz and can extend up to 10,000 Hz. Cavitation generally refers to the formation of vapor bubbles in a liquid in areas of low pressure that occurs where the liquid is accelerated to high velocities, such as during the operation of centrifugal pumps, water turbines, and marine propellers.
[0005] Thus, underwater radiated noise and cavitation are commonly encountered in marine environments due to the use of ships, such as container or tanker ships.
[0006] Introduction The following preamble is intended to introduce the reader to the present specification and does not define any invention. One or more inventions may reside in a combination or subcombination of the compositions or method steps described below, or elsewhere in this document. The inventors do not waive or disclaim any rights to any invention disclosed herein by merely not reciting other inventions in the claims.
[0007] coating
[0008] For example, with increasing awareness of the impact of underwater radiated noise (URN) on the environment, coatings that reduce radiated noise are expected to play an increasingly important role in the coatings market. URN can impact the environment by increasing noise pollution, which in turn can have detrimental effects on marine animals. It is recognized that operational marine vessels, such as container or tanker ships, can emit a wide range of frequencies that can interfere with animals' ability to communicate, hunt, migrate, and echolocate. For example, URN includes sounds that are emitted at frequencies below 100 Hz and can extend up to 10,000 Hz. Research suggests that the primary sources of URN on marine vessels are engines and propellers, with engines generating low frequencies (e.g., 100-500 Hz) that can disturb larger marine animals, and propellers generating high frequencies (e.g., 1000-10,000 Hz) that can disturb smaller marine organisms.
[0009] Measures to minimize URN that have been investigated include dispersing radiated noise by widening engine reinforcements, limiting noise by adding dampers to the engine, investigating propeller blade designs, conducting hydrodynamic tests to evaluate propeller efficiency and cavitation reduction, improving sound insulation with acoustic enclosures, and developing coatings to reduce noise. For example, some marine vessels, such as submarines and ships, use rubber tiles or mounts on their engines to reduce URN. Other marine vessels may use coatings formed from compositions based on "armor" rubber resins (e.g., rubber resins with reinforcing fibers, particles, etc.) and having ingredients such as barium sulfate, acrylic microgels, etc. Such coatings are often applied in layers of 1000-3000 μm thickness to provide a sufficient amount of URN reduction, as well as corrosion protection for the vessel's hull.
[0010] Coatings that reduce cavitation are also expected to play an increasingly important role in the coatings market. Cavitation is a generally undesirable phenomenon in which the static pressure of a liquid becomes lower than the liquid's vapor pressure, forming small vapor-filled cavities in the liquid. When subjected to higher pressures, these cavities, sometimes called "bubbles" or "voids", can collapse and generate shock waves that can cause damage. Cavitation can occur in propellers. As the propeller blades move through a fluid, such as fresh or saltwater, low-pressure areas are created as the fluid accelerates past the blades. The faster the blades move, the lower the pressure around them can be. When vapor pressure is reached, the fluid vaporizes, forming small bubbles of gas. These bubbles collapse when they reach areas of higher pressure. When they collapse, very strong localized shock waves can be generated in the fluid. This results in underwater radiated noise, which can have serious environmental effects as mentioned above.
[0011] The collapse of these bubbles can also cause damage to components, vibration, and / or reduced efficiency. For example, the collapse of these bubbles can cause pitting on the propeller blade surface. After pitting occurs, the propeller can corrode at an accelerated rate. Pitting can also increase turbulence in the fluid flow, reducing efficiency due to distorted flow patterns, and can create crevices that act as nucleation sites for cavitation bubbles. Pitting can also increase the surface area of the propeller blade, creating residual stresses.
[0012] Therefore, coatings that improve corrosion resistance by increasing hardness and / or scratch resistance are also expected to play an increasingly important role in the coatings market in light of environmental regulations. Corrosion is a chemical process in which metals are converted into other forms, such as metal oxides, hydroxides, or sulfides, and is the gradual destruction of materials (usually metals) by chemical and / or electrochemical reactions with the environment. Corrosion typically occurs in objects exposed to water and / or moisture, such as objects exposed to weather, salt water, and other electrolytes, and other harsh environments.
[0013] Solvent-based monomer based coatings
[0014] Solvent-borne monomers, also called solvent-based resins, are generally widely available commercially and include resins such as aryl resins, amino resins (also called aminoplasts), polyester resins, bismaleimide (BMI) resins, cyanate ester resins, furan resins, phenolic resins, polyurea resins, polyurethane resins, silicone resins, vinyl ester resins, epoxy resins, and / or hybrid silicone-epoxy resins. Solvent-borne monomers can be reacted (e.g., "crosslinked" or "cured") with a wide range of curing agents via a polymerization / crosslinking reaction to form an infusible, insoluble polymer network on the surface of the substrate. Such curing agents can include acids (and acid anhydrides), phenols, alcohols, thiols, multifunctional amines, phenalkamines, amine-modified phenalkamines, amides, phenalkamides, amine-modified phenalkamides, silamines, or combinations thereof.
[0015] Solvent-based monomers refer to monomers dispersed in a substantially anhydrous solvent, which constitute the main film-forming component of the resulting cured coating. Solvent-based monomers are generally used in solvent-based compositions that are essentially or substantially anhydrous. Some additives in solvent-based compositions contain some amount of water / water solution, but since these additives are not the main film-forming component (solvent-based monomer), the amount of water introduced is not sufficient to make the composition a waterborne composition. Curing of solvent-based compositions involves polymerization and / or crosslinking reactions to form an infusible and insoluble polymer network.
[0016] Contrast with solvent-based compositions are water-based and powder compositions. Water-based compositions are water-soluble compositions in which the primary film-forming component comprises water-based monomers, i.e., monomers dispersed in a substantially aqueous solution or solvent, often in the form of a latex. Curing of water-based compositions generally does not involve polymerization and / or crosslinking reactions to form covalent bonds, but instead involves other mechanisms involving physical fusion of polymeric latex particles into a polymeric monolith and evaporation of the aqueous medium to form the cured coating. As a result, cured coatings formed from water-based compositions are generally not suitable for use in wet environments, and the lack of an infusible, covalently crosslinked, insoluble polymer network results in peeling, bubbling, or other loss of adhesion of the coating to the surface or substrate to which the water-based composition is applied. Powder compositions, also referred to as powder coatings, are compositions based on polymer resin systems and other additives that are melt mixed, cooled, and ground into a uniform powder. Generally, powder compositions are substantially free of solvents or contain minimal solvents. Powder compositions are typically applied to metal substrates due to the need to apply electrostatic spray deposition (ESD). In ESD, the powder composition is sprayed from an electrostatic gun onto a grounded metal surface. The charge imparted to the powder by the gun attracts it to the grounded metal surface. The coating is cured at a specific temperature, which varies depending on the coating being applied. After application of the powder coating, the coated metal surface is cured in a curing oven where the application of heat causes the powder coating to chemically react to produce long molecular chains resulting in a high cross-link density. As a result, powder coatings are generally not widely applicable, for example, to marine vessels for use in wet environments, and high temperature curing of vessel hulls may not be possible in dry docks, since not all vessels are made of metal.
[0017] Coatings cured from solvent-based monomers are not known to have significant sound deadening properties, and therefore do not generally provide substantial reduction in URNs generated by marine vessels when used on marine vessels. Furthermore, curable compositions containing solvent-based monomers tend to be too expensive and time consuming to apply the curable coatings at thicknesses that may otherwise be required to provide sufficient sound deadening properties. Coatings cured from solvent-based monomers are also not known to have significant cavitation resistance, and therefore do not generally provide substantial reduction in cavitation generated by marine vessel propellers when used on marine vessels. Furthermore, after application to a substrate, coatings cured from solvent-based monomers can provide some initial corrosion resistance. However, defects in the coating or damage, such as scratches or wear, can result in water penetration over time, such as after several years. This can result in wear and tear of the coating, necessitating the application of a new coating.
[0018] Compositions, Uses, and Methods of the Disclosure
[0019] One or more embodiments of the present disclosure seek to provide a composition that can be used to form a cured coating. In one or more embodiments, the present disclosure provides a composition that includes a solvent-based monomer, a diluent, an adhesion promoter, and hollow ceramic spheres. In one or more embodiments, the present disclosure provides a composition that includes a solvent-based resin, a diluent, an adhesion promoter, a rheology modifier, and a ceramic performance additive.
[0020] The solvent-based monomers of the composition, also referred to herein as solvent-based resins, provide a film-forming base for forming the cured coating and include any one or combination of liquid monomers or prepolymers, such as allylic resins, amino resins (also referred to as aminoplasts), polyester resins, bismaleimide (BMI) resins, cyanate ester resins, furan resins, phenolic resins, polyurea resins, polyurethane resins, silicone resins, vinyl ester resins, epoxy resins, and / or hybrid silicone-epoxy resins. In one or more embodiments, the solvent-based monomers include solvent-based epoxy resins, also referred to as epoxy-functional monomers, which can react through epoxide functional groups to form an infusible, insoluble polymer network comprising polymerized and / or crosslinked epoxy-functional monomers.
[0021] Generally, coatings cured from solvent-based monomers are not known to have significant sound deadening properties, nor are they generally known to have significant cavitation resistance. Additionally, some examples of coatings cured from solvent-based monomers are not hard enough after curing to provide scratch or abrasion resistance, which can affect the mechanical integrity of the coating and subsequently the corrosion resistance that the coating provides over time.
[0022] In one or more embodiments, a ceramic performance additive is added to the composition. The ceramic performance additive can be added to the composition to enhance the sound deadening properties of the cured coating, or the ceramic performance additive can be added to the composition to enhance the hardness (alternatively as measured by scratch resistance (abrasion resistance)) of the cured coating, or a combination thereof. In one or more embodiments, when the ceramic performance additive is added to the composition to enhance scratch resistance by increasing hardness, the ceramic performance additive can also be used to enhance cavitation resistance. The ceramic performance additive can include hollow ceramics and non-hollow ceramics. As used herein, "non-hollow" refers to particles that do not have a hollow core, or particles that do not have a substantially hollow core. The hollow ceramics and non-hollow ceramics can have a Mohs hardness of about 5 to about 10, or about 6 to about 9. The hollow ceramics can include hollow ceramic spheres that can have a shape that is spherical, substantially spherical, spherical-like, spheroidal, substantially spheroidal, spheroidal, or a combination thereof. The hollow ceramic spheres may have a particle size of about 20 μm to about 40 μm and may be present in a range of about 30 wt% to about 70 wt% based on the weight % of part A. The hollow ceramic spheres may have a particle size of about 10 μm to about 15 μm and may be present in a range of about 5 wt% to about 70 wt% based on the weight % of part A. The non-hollow ceramic may include non-hollow ceramic particles such as titanium oxide, fumed silica, brown aluminum (III) oxide, fused aluminum (III) oxide, titanium alloys, or combinations thereof. The non-hollow ceramic particles may have a particle size of about 0.1 μm to about 5 μm and may be present in a range of about 10 wt% to about 50 wt% based on the weight % of part A.
[0023] In one or more embodiments, hollow ceramic spheres are added to the composition to enhance the sound deadening properties of the cured coating. In one or more embodiments, the hollow ceramic spheres may have a size of about 20 μm to about 40 μm, a hollow core, a ceramic composition, and / or a weight percent loading in the composition of about 30% to about 70% by weight, which is approximately equivalent to a volume percent loading of about 15% to about 55% by volume (based on a density of about 1 to about 3, or about 2 to about 2.5). Without wishing to be bound by theory, the use of hollow ceramic spheres can at least provide a sufficient concentration of air-filled voids in the cured coating to improve the sound deadening properties, and / or at least destructively (or reflectively) interfere with the radiated sound waves to improve the sound deadening properties. In one or more embodiments, when hollow ceramic spheres are added to the composition to improve the sound deadening properties of the cured coating, the resulting cured coating can be applied to a substrate as an undercoat, to which a topcoat can be further applied. In one or several embodiments, the applied topcoat can be selected to provide anti-fouling / fouling release properties or other desired properties consistent with the end use of the coating and / or the substrate to which it is applied. In some embodiments, the hollow ceramic spheres having a size of about 20 μm to about 40 μm and / or a weight percent loading in the composition of about 30% to about 70% by weight also enhance the hardness or scratch resistance of the cured undercoating. In some embodiments, the hollow ceramic spheres increase the hardness or scratch resistance of the cured undercoating to at least 5H as measured according to ASTM D3363.
[0024] In one or more embodiments, hollow ceramic spheres are added to the composition to increase the hardness (or as measured by scratch resistance) of the cured coating. In one or more embodiments, the hollow ceramic spheres may have a size of about 10 μm to about 40 μm, a weight percent loading in the composition of about 5% to about 15% by weight, based on the weight percent of the hollow core, ceramic composition, and / or Part A. In one or more embodiments, the hollow ceramic spheres may have a size of about 10 μm to about 15 μm, or about 20 μm to about 40 μm, a weight percent loading in the composition of about 5% to about 20% by weight, or about 5% to about 15% by weight. Without wishing to be bound by theory, the use of hollow ceramic spheres may improve at least the scratch and abrasion resistance due to the ceramic spheres' high hardness (e.g., 7 on the Mohs scale), in some embodiments, their smaller size (e.g., about 12 μm), or loading rate, which can provide a relatively smooth surface. In one or more embodiments, when the scratch resistance of the cured coating is improved by adding hollow ceramic spheres to the composition, the resulting cured coating can be applied to a substrate as a topcoat and further formulated to provide anti-fouling / foul release properties or other desired properties consistent with the end use of the coating and / or the substrate to which it is applied.
[0025] In one or more embodiments, the addition of non-hollow ceramic particles to the composition increases the hardness (or as measured by scratch resistance) of the cured coating. In one or more embodiments, the non-hollow ceramic particles can have a size of about 0.1 μm to about 5 μm, a weight percent loading in the composition of about 5% to about 40% by weight, or about 10% to about 20% by weight, based on the weight percent of the ceramic composition and / or Part A. Without wishing to be bound by theory, the use of non-hollow ceramic particles may improve at least the scratch and abrasion resistance due to the inherent hardness of the ceramic material (e.g., about 5 to about 10, or about 7 to about 9 on the Mohs scale), the small particle size, and / or the loading rate, which can impart a relatively smooth surface. In one or more embodiments, where the scratch resistance of the cured coating is improved by adding non-hollow ceramic particles to the composition, the resulting cured coating can be applied to a substrate as a topcoat and further formulated to provide anti-fouling / foul release properties or other desired properties compatible with the end use of the coating and / or the substrate to which the coating is applied.
[0026] In one or more embodiments, the inclusion of a diluent in the composition aids in reducing the viscosity, thereby improving the processability of the composition. In one or more embodiments, the addition of a diluent to act as a liquid vehicle can provide a composition viscosity of 3500 cps or less. In one or more embodiments, the diluent can have a lower viscosity than the solvent-based monomer, for example, less than 1000 cps, for example, from about 1 cps to about 800 cps. In some embodiments, the diluent comprises a reactive diluent that is reactive in the polymerization of the solvent-based monomer (e.g., contains reactive functional groups, such as hydroxyl or epoxide functional groups, that can at least react with the solvent-based monomer), a non-reactive diluent (e.g., does not contain reactive functional groups), or a combination thereof.
[0027] In one or more embodiments, the inclusion of an adhesion promoter in the composition at least increases the flexibility of the cured coating obtained from the composition, e.g., as indicated by a flexural strength of at least 10 mm when measured in a cylindrical bend test. In one or more embodiments, when the cured coating is applied as an undercoat, the inclusion of an adhesion promoter can improve the intercoat adhesion between the cured undercoat and any topcoat that may be applied. The adhesion promoter can improve the flexibility and / or recoat adhesion of the cured coating formed from the composition due to the reactive groups of the promoter. In one or more embodiments, the adhesion promoter has at least two, or at least three functional groups that can couple with ceramic performance additives, such as hollow ceramic spheres, and / or can be incorporated into the polymerization of solvent-based monomers. In one or more embodiments, the adhesion promoter can act as a binder between the ceramic performance additives, such as hollow ceramic spheres, and the solvent-based resin to improve the flexibility of the cured coating containing the hollow ceramic spheres. In some embodiments, the adhesion promoter can improve the cohesion of the cured coating. Cohesion here refers to the mechanical strength of a single cured coating layer and how well it resists peeling, compressive, bending, or any other damaging forces. In one or more embodiments, when the cured coating is applied as an undercoat, the adhesion promoter can act as a bonding agent between the cured undercoat and any topcoat that may be applied, improving intercoat adhesion. In one or more embodiments, the adhesion promoter is a silane, such as an alkyloxy-functionalized silane.
[0028] In one or more embodiments, the inclusion of an adhesion promoter in the composition at least increases the adhesion of the cured coating resulting from the composition to a metal substrate or a primed metal substrate. In one or more embodiments, the adhesion promoter in combination with the curing agent composition can increase the adhesion of the cured coating resulting from the composition to a metal substrate or a primed metal substrate. In one or more embodiments, when the curable coating is applied directly to a metal substrate, the inclusion of an adhesion promoter can improve the substrate adhesion between the cured coating and the metal substrate. In one or more embodiments, when the cured coating is applied to a primed metal substrate, the inclusion of an adhesion promoter in both the primer composition and the coating composition can improve the substrate adhesion between the cured coating and the primed metal substrate. The metal substrate can be a steel substrate, a copper substrate, a copper alloy substrate, an aluminum substrate, an iron substrate, or other metal substrate. The adhesion promoter can be a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof. The dry adhesion promoter, dry / wet adhesion promoter, and / or wet adhesion promoter may be non-reactive, reactive in epoxy polymerization, reactive with metal substrates, and / or reactive with surface oxides on metal substrates, or combinations thereof.
[0029] In one or more embodiments, the dry adhesion promoter is non-reactive, reactive in epoxy polymerization, reactive with the substrate, and / or reactive with metal oxides. In one or more embodiments, the dry adhesion promoter may include one or more functional groups capable of reacting with inorganic surfaces (e.g., ceramic, surface oxides on metal substrates). The dry adhesion promoter may also include one or more functional groups capable of reacting with epoxide polymerization and solvent-based epoxy resins, thereby enhancing the adhesion of the resulting coating to the metal substrate (e.g., Cu substrate). In one or more embodiments, the dry adhesion promoter includes an alkoxylated silane. In one or more embodiments, the wet adhesion promoter is reactive with the metal substrate. In one or more embodiments, the wet adhesion promoter may be activated in a wet environment by decomposing in the presence of ions in the water that permeates the coating. The products of this decomposition may react with the metal substrate, such as a Cu alloy, an Al alloy, or an Fe alloy, and may also cross-react with undecomposed adhesion promoter. This may form a strong bond complex between the coating layer and the metal substrate. This may also prevent corrosion of the substrate. In one or more embodiments, the wet adhesion promoter comprises a metal-doped phosphosilicate. In one or more embodiments, the dry / wet adhesion promoter is non-reactive, reactive with the substrate, and / or reactive with metal oxides. In one or more embodiments, the dry / wet adhesion promoter can provide good flow properties that help the curable coating flow into rough areas on the metal substrate, which can facilitate the formation of a grip between the cured coating and the substrate. In one or more embodiments, the dry / wet adhesion promoter can include one or more functional groups that can react with the metal substrate. The dry / wet adhesion promoter can also include one or more functional groups that are reactive in epoxide polymerization and can react with solvent-based epoxy resins.In one or more embodiments, the dry / wet adhesion promoter comprises a modified polyester, a modified polyester oligomer, a polyacrylic acid, a polyacrylate, a benzotriazole, a polymer or prepolymer comprising a mercaptan, a hydroxyphenyl-benzotriazole, a hydroxyphenyl-triazine, or a combination thereof.
[0030] In one or more embodiments, the inclusion of a rheology modifier in the composition provides a curable coating or coating formed from the composition with anti-settling, anti-sagging or surface leveling properties. In one or more embodiments, the inclusion of an anti-settling rheology modifier in the composition at least reduces settling of the ceramic performance additive in the composition or the curable composition. In one or more embodiments, the anti-settling rheology modifier comprises silica, clay, or combinations thereof, such as fumed silica, fumed silica surface modified with silane, fumed silica surface modified with dimethyldichlorosilane, aluminum phyllosilicate clay, organo-modified derivatives of aluminum phyllosilicate clay, organo-modified bentonite clay, organo-modified montmorillonite clay, or combinations thereof. In one or more embodiments, the inclusion of an anti-sagging rheology modifier in the composition at least reduces sagging or dripping of the curable coating after it is applied onto a substrate. For example, it prevents the coating composition from dripping off a substrate, such as a vertical substrate, when sprayed. In one or more embodiments, the anti-sag rheology modifier comprises a wax, a micronized wax, or a combination thereof, such as a polyamide wax, a micronized polyamide wax, a micronized organically modified polyamide wax, a micronized organically modified polyamide wax derivative, or a combination thereof. In one or more embodiments, the inclusion of a surface leveling rheology modifier in the composition provides at least a smoother leveling of the curable coating when applied, and reduces the formation of craters or cavities in the curable coating. In one or more embodiments, the surface leveling rheology modifier comprises a polyether siloxane copolymer.
[0031] In some embodiments, the rheology modifiers included in the composition include aluminum phyllosilicate clays, organically modified derivatives of aluminum phyllosilicate clays, organically modified bentonite clays, organically modified montmorillonite clays such as Claytone-HY or Claytone-APA, organically modified castor oil derivatives such as Thixatrol ST, micronized organically modified derivatives of polyamide waxes such as Crayvallac Super, fumed silica, fumed silica surface-modified with dimethyldichlorosilane such as Cab-O-Sil 610, micronized barium sulfate such as VB Techno, microcrystalline magnesium silicate such as Talc Silverline 202 or Mistron 002, or combinations thereof. Some examples of rheology modifiers included in the composition may have partial rheology modifying properties (such as barium sulfate) or complete rheology modifying properties. Inclusion of such modifiers in the composition can reduce sagging of the curable composition when applied to a substrate, allow for a more uniform and / or high build application of the composition to a substrate, and / or promote the formation of a cured coating having a more uniform surface. In some embodiments, the rheology modifier can improve the long term packaging stability or shelf life of the pre-cured composition and / or can improve the anti-settling properties of the pre-cured composition.
[0032] One or more compositions of the present disclosure can be used to form a cured coating by reacting the composition with a curing agent, which can also be said to cure the composition to form a cured coating. The curing agent can induce, and in some cases participate in, a reaction (e.g., polymerization and / or crosslinking) that converts at least the solvent-based monomers into an infusible, insoluble polymer network (sometimes referred to as a cured coating). For example, the curing agent can be reactive in the solvent-based monomer polymerization and thus can induce polymerization and act as a crosslinker in the reaction. In one or more embodiments, the curing agent includes polyfunctional acids (and anhydrides), phenols, alcohols, and thiols, or polyfunctional amines, amides, or combinations thereof. In other embodiments, the curing agent includes amine curing agents, amide curing agents, or combinations thereof. In one or more embodiments, the curing agent is reactive in curing the composition to form a coating that is resistant to at least 50 passes, or 50-80 passes, of organic solvent abrasion, as measured according to ASTM D1640. In some embodiments, the curing agent may include an amine curing agent, an amide curing agent, or a combination thereof, such as phenalkamine, amine-modified phenalkamine, phenalkamide, amine-modified phenalkamide, polyaminoamide, organically modified polyamidoamine, or a combination thereof, or a silamine curing agent, such as aminopropyltriethoxysilane.
[0033] In one or more embodiments, the cured coating formed from the composition of the present disclosure is formed on a substrate. The substrate can include a surface to which the coating composition can be applied. In one or more embodiments, the substrate is a surface of a marine vessel (e.g., a boat, a ship, etc.), such as a hull or a propeller.
[0034] One or more embodiments of the present disclosure seek to provide compositions that can be used to form cured coatings that exhibit sound deadening properties, improved hardness, improved substrate adhesion, overcoat adhesion, recoat adhesion, or at least 10 mm flexural strength (compared to a control). In some embodiments, the adhesion promoter is included in the composition in an amount sufficient to provide a coating formed from the composition having an intercoat adhesion of at least 5 MPa as measured according to ASTM D4541, or a flexural strength of at least 10 mm as measured in a cylindrical bend test (compared to a control). In some embodiments, the adhesion promoter is included in the composition in an amount sufficient to provide a coating formed from the composition having a substrate adhesion of at least 3 MPa as measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa as measured according to ASTM D4541, or a recoat adhesion window of at least 4 hours as measured according to ASTM D3359. In some embodiments, the hollow ceramic spheres are provided in an amount sufficient to provide a coating formed from the composition having reduced noise emissions of from about 1 dB up to about 40 dB, 50 dB, 10 dB per about 100 μm of coating thickness at frequencies of about 1000 Hz or less, as measured on a 3 mm thick cold rolled steel sheet, as compared to an uncoated 3 mm thick steel sheet, or a hardness of at least 5H (as compared to a control) as measured according to ASTM D3363. In some embodiments, the ceramic performance additive is provided in an amount sufficient to provide a coating formed from the composition having reduced noise emissions of from about 2 dB to about 10 dB per about 100 μm of coating thickness at frequencies of from about 10 Hz to about 10 kHz, as measured on a 3 mm thick cold rolled steel sheet, as compared to a 3 mm thick cold rolled steel sheet coated with a coating that does not include the ceramic performance additive.
[0035] Additionally, one or more embodiments of the present disclosure provide a method of forming one or more of the compositions described above. In one or more embodiments, the method includes mixing together a solvent-based monomer, a diluent, an adhesion promoter, and hollow ceramic spheres, and forming a coating composition. In one or more embodiments, the method further includes mixing a rheology modifier, a dispersant, an antifoaming agent, and / or an antiwear agent. In one or more embodiments, the method includes mixing together a solvent-based resin, a diluent, an adhesion promoter, a rheology modifier, and a ceramic performance additive, and forming a coating composition. In one or more embodiments, the method further includes mixing a dispersant, an antifoaming agent, and / or an antiwear agent. [Brief description of the drawings]
[0036] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying figures.
[0037] [Figure 1] FIG. 1 shows the experimental sound insulation setup for measuring the sound deadening properties of cured coatings formed from the compositions of the present application.
[0038] [Diagram 2] FIG. 2 shows the intercoat adhesion and flex testing for cured coatings formed from formulations BC169.5 and BC169.6 of Example 1.
[0039] [Diagram 3] FIG. 3 illustrates an example of the application of a cured composition of the present disclosure to a metal surface of a substrate.
[0040] [Figure 4] FIG. 4 illustrates an example of the application of a cured composition of the present disclosure to a fiberglass surface of a substrate.
[0041] [Diagram 5]FIG. 5 shows the crosshatch tape adhesion test performed to measure the intercoat or recoat adhesion of (A) Formulation 212.2 and (B) Formulation 212.4, and (C) shows a visual comparison chart to grade the performance of the coatings by the crosshatch test.
[0042] [Figure 6] FIG. 6 shows the relative coating sag results for formulations (A) 158-URN2_SP1, (B) 158-URN2_SP2 (C) 158-URN2_ZP1 / SP1, (D) 156.Blank.2, (E) 169-URN3-3.2.
[0043] [Figure 7] FIG. 7 shows (A) the Elcometer peel adhesion device for testing adhesion to steel, and test results for (B) URN formulation 200.2 (5 MPa), and (C) URN formulation 200.1 (7 MPa).
[0044] [Figure 8] FIG. 8 shows the blister and permeability test results for formulations (A) BC169_URN3-3.2 on primer coating, (B) BC169_URN3-3.2 on bare steel, (C) 242 on primer, (D) 242 on bare steel.
[0045] [Figure 9] FIG. 9 shows Cu adhesion test results for PROP formulations (A) 230.14 (dry adhesion) on primer (parallel test readings: 3.5, 5.0, 5.0, and 5.0 MPa), (B) 184 (dry adhesion 2 MPa) without primer (parallel test readings: 2.0 and 2.0 MPa), (C1) 230.14 (wet adhesion) on primer (parallel test readings: 6 MPa for image C1 and "fail" equivalent to 1 MPa for image C2), (C2) 230.14 (wet adhesion) without primer, (D) 243.1 (wet adhesion) without primer (parallel test readings: 6.5, 6.0, and 5.0 MPa).
[0046] [Figure 10] FIG. 10 shows the flexural strength test results of PROP formulations (A) 184.Base, (B) 210.5, and (C) 210.6.
[0047] [Figure 11] FIG. 11 shows the cavitation resistance test setup (large propeller), including (A) a trolling motor engine, (B) a full-scale cavitation test setup, (C) the propeller portion of a trolling motor with the propeller attached to the head, and (D) the propeller underwater.
[0048] [Figure 12] Figure 12 shows the results of cavitation resistance testing (large propeller) after two months of constant operation in seawater. Three sections of the propeller were separately treated with PROP coatings formed from Formulation 243.5 (A), primed PROP Formulation 230.14 (B), and a single coat of PROP Formulation 243.1 applied directly to Cu (C).
[0049] [Figure 13] Figure 13 shows the wet Cu adhesion and cavitation resistance performance of a primed PROP coating made from Formulation 230.14 (D) in a double coat (A) and a PROP coating made from Formulation 243.1 (C) applied directly to a Cu propeller in a single coat (B). The enlarged portions of (C) and (D) show the coating after approximately 2-3 months of testing, while the reduced portions show the starting point.
[0050] [Figure 14] FIG. 14 shows the microstructures before and after cavitation testing (2 months of continuous operation) of (A) the PROPSPEED topcoat before cavitation testing, (B) the coating formed from Formulation 230.14 before cavitation testing, (C) the PROPSPEED topcoat after cavitation testing, and (D) the coating formed from Formulation 230.14 after cavitation testing. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] definition
[0052] 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 invention belongs.
[0053] As used in this specification and claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.
[0054] As used herein, the term "comprising" indicates that the list below is non-exhaustive and may or may not include any other additional suitable items, e.g., one or more further features, components and / or ingredients, as appropriate.
[0055] As used herein, (a) "coating composition," (b) "coating composition," (c) "pre-cured composition," or (d) "pre-cured coating composition" refers to a composition of the present disclosure that has not yet been reacted or cured with a curing agent to form a coating.
[0056] As used herein, (a) "a coating formed from the composition," (b) "a coating formed from the coating composition," (c) "cured coating," or (d) "cured epoxy-based coating" refers to a coating comprising the reaction product of a composition of the present disclosure and a curing agent (i.e., a coating that has been cured).
[0057] As used herein, "control" refers to (i) (a) a "coating without such additives," (b) a "control coating," or (c) a "control epoxy-based coating," which refer to a coating consisting of the reaction product of a curing agent and a composition consisting of a solvent-based monomer or an epoxy-functional monomer, suitably diluted, and / or (ii) an uncoated substrate (e.g., a 3 mm thick cold-rolled steel sheet).
[0058] As used herein, a "curing composition" refers to a pre-cured composition that has been mixed with a curing agent but has not yet cured to form a cured epoxy-based coating.
[0059] As used herein, "incorporated into the polymerization" refers to a compound or molecule (e.g., additive, monomer, oligomer, prepolymer) that contains functional groups that are reactive in the polymerization of solvent-based monomers, reactive in epoxide polymerization, reactive with side, pendant, terminal, or end groups of solvent-based monomers, and / or reactive with side, pendant, terminal, or end groups of epoxy-functional monomers (e.g., siloxane / silicone / polysiloxane side chains), such that the compound or molecule acts as a reagent (e.g., monomer, crosslinker, etc.) in the reaction. As used herein, "entrapped during polymerization" refers to a compound or molecule (e.g., additive, monomer, oligomer, prepolymer) that becomes physically entangled in the infusible, insoluble polymer network (cured coating) as it is formed.
[0060] As used herein, "monomer" or "resin" refers to (i) a monomer or monomer system capable of polymerization to higher molecular weight through reactive groups, such as a cured coating, and / or (ii) a prepolymer (which refers to a monomer or monomer system that has been reacted to an intermediate molecular weight state that is capable of further polymerization to higher molecular weight through reactive groups, such as a cured coating). A mixture of reactive polymer and unreacted monomer is sometimes referred to herein as "monomer" or "resin."
[0061] As used herein, "A, B, ...X, and / or Y" refers to "A, B, ...X, and Y", or "one of A, B, ...X, or Y", or "any combination of A, B, ...X, and Y".
[0062] As used herein, "Part A of the coating composition" refers to the component of the coating composition that does not include the hardener composition (also referred to herein as Part B). As used herein, "Part B of the coating composition" refers to the component of the hardener composition.
[0063] As used herein, "based on the weight percent of Part A" refers to the weight percent of a component relative to the total weight percent of Part A of the coating composition. As used herein, "based on the total weight percent" refers to the weight percent of a component relative to the weight percent of Parts A and B of the coating composition. Generally, the total weight percent is about 1.5 times lower than the weight percent per Part A.
[0064] "Reactive in epoxy polymerization" or "reactive in the polymerization of solvent-based monomers" when used in the context of an additive or diluent as described herein refers to comprising or containing reactive functional groups that can at least react with a solvent-based monomer or an epoxy-functional monomer as described herein to form an infusible, insoluble polymer network (cured coating as described herein). "Reactive in epoxy polymerization" or "reactive in the polymerization of solvent-based monomers" when used in the context of a curing agent as described herein refers to (a) inducing curing of a pre-cured composition, (b) being incorporated (e.g., covalently as a monomer and / or crosslinker) into the polymerization of at least a solvent-based monomer when the pre-cured composition is cured to form a cured coating, or (c) comprising or containing reactive functional groups that can at least react with a solvent-based monomer as described herein to form an infusible, insoluble polymer network (cured coating as described herein).
[0065] As used herein, "non-reactive" refers to a compound or molecule (e.g., a diluent, adhesion promoter, additive, monomer, oligomer, prepolymer) that does not contain functional groups that are reactive in the polymerization of solvent-based monomers, does not contain functional groups that are reactive in epoxide polymerization, does not contain functional groups that are reactive with the surface oxide of the substrate, and / or does not contain functional groups that form covalent bonds with another compound or molecule, such that the compound or molecule does not act as a reagent (e.g., a monomer, crosslinker, coupling agent, etc.) in a reaction.
[0066] As used herein, "ceramic" refers to materials that are inorganic non-metallic solids, including metal oxides and compounds of metallic elements with carbon, nitrogen, or sulfur. Ceramics may contain a combination of amorphous and crystalline phases, but are often crystalline, and are recognized for properties such as hardness that contributes to resistance to abrasion and cavitation erosion, thermal and electrical conductivity that is significantly lower than that of metals, and / or the ability to achieve decorative, slippery finishes.
[0067] As used herein, "phosphosilicate" also refers to phosphate-silicate.
[0068] As used herein, "filler" generally refers to an inorganic material, typically in the form of a powder, that can be used to reduce the amount of resin required in a composition. Depending on the type of resin, the cost of the resin per kg may be more than 5-10 times that of the filler, and fillers may be used instead of the resin to reduce costs. Fillers can also be used to improve the properties of the cured coating compared to the control coating, such as barrier performance, corrosion resistance, hardness, and matte effect. For example, barium sulfate, talc, or wollastonite. In this specification, barium sulfate can be used as a rheology modifier, but can also be used as a filler with viscosity reducing properties.
[0069] As described herein, each component included in a coating composition may have chemical or physical properties that allow the component to perform multiple functions or serve multiple purposes in the composition and the coating formed therefrom. For example, as described herein, titanium dioxide, titanium carbide, aluminum oxide, or fumed silica may be used as a ceramic performance additive, which, when included in a pre-cured composition, may increase the hardness of the cured coating by having a Mohs hardness of about 6-9. However, as also described herein, titanium dioxide and fumed silica may be used as anti-wear agents that may increase the abrasion resistance of the cured coating due to their abrasion resistance. Distinguishing titanium dioxide and fumed silica as both ceramic performance additives and anti-wear agents is not an inconsistent act, but rather an indication that these components may serve different functions or purposes in the cured coating. Thus, as described herein, distinguishing a component as being two or more different types of composition additives is an indication of the different functions or purposes that the component may serve in the pre-cured composition or cured coating.
[0070] As used herein, the terms "modified" or "derivatives", such as "castor oil derivative wax" or "organically modified castor oil derivative wax", are used in the context of the chemical name of the component or additive. When used in this context, terms such as "modified" or "derivatives" are recognized in the art as indicating a class or type of component or additive and / or its general chemical and physical properties. When used in this context, terms such as "modified" or "derivatives" still allow for the identification, selection, and / or purchase of a suitable component or additive for use in the coating compositions described herein.
[0071] Solvent-based Monomers
[0072] As noted above, one or more embodiments of the present disclosure provide a composition that can be used to form a cured coating (aka a pre-cured composition), the composition comprising a solvent-based monomer (aka a solvent-based resin) that provides the primary film-forming component of the cured coating described herein and thus provides a base for forming the coating (aka forming the continuous matrix of the coating film), and includes one or a combination of liquid monomers or prepolymers that contain reactive functional groups for polymerization.
[0073] In one or more embodiments, the solvent-based monomer of the composition comprises any one or combination of liquid monomers or prepolymers (also referred to as solvent-based resins), such as allyl resins, amino resins (also referred to as aminoplasts), polyester resins, bismaleimide (BMI) resins, cyanate ester resins, furan resins, phenolic resins, polyurea resins, polyurethane resins, silicone resins, vinyl ester resins, and / or epoxy resins (also referred to as epoxides). In some embodiments, the solvent-based monomer comprises an allyl-functional monomer, an amino-functional monomer, a maleimide-functional monomer, a cyanate ester-functional monomer, an epoxy-functional monomer, a furan-functional monomer, a vinyl ester-functional monomer, or a combination thereof. In other embodiments, the solvent-based monomer comprises a solvent-based prepolymer, such as an allyl-functional prepolymer, an amino-functional prepolymer, a polyester prepolymer, a bismaleimide prepolymer, a cyanate ester-functional prepolymer, an epoxy-functional prepolymer, a furan-functional prepolymer, a phenolic prepolymer, a polyurea prepolymer, a polyurethane prepolymer, a silicone prepolymer, or a vinyl ester-functional prepolymer.
[0074] In one or more embodiments, allyl resins include clear, wear-resistant synthetic resins or plastics typically formed from esters derived from allyl alcohol or allyl chloride. In one or more embodiments, amino resins (also called aminoplasts) include prepolymers formed by copolymerization of amines or amides with aldehydes, including urea-formaldehyde resins and melamine-formaldehyde resins. In one or more embodiments, polyester resins include unsaturated synthetic resins formed by the reaction of dibasic organic acids with polyhydric alcohols. For example, maleic anhydride is a commonly used raw material with diacid functionality. In one or more embodiments, bismaleimide (BMI) resins include those formed by the condensation reaction of diamines with maleic anhydride and processed (350°F (177°C) cured) similarly to epoxy resins. In one or more embodiments, the cyanate ester resins include those formed from the reaction of bisphenol or multifunctional phenol novolac resins with cyanogen bromide or chloride to obtain cyanate functional monomers that can be converted in a controlled manner to cyanate ester functional prepolymer resins by chain extension or copolymerization. In one or more embodiments, the furan resins include prepolymers made from furfuryl alcohol or by modification of furfural with phenol, formaldehyde, urea or other extenders, which are cured by polycondensation and release of water and heat. Although furan resins are generally cured under the influence of heat, catalysts, and pressure, in some embodiments, they can also be formulated as two-component non-baking acid-curing systems characterized by high resistance to heat, acid, and alkali.
[0075] In one or more embodiments, the phenolic resins include products of phenol derivatives, such as phenol resorcinol, with aldehydes, such as formaldehyde furfural, and may include novolacs and resoles. In some embodiments, novolacs may be formed using acid catalysts and a molar ratio of formaldehyde to phenol less than 1 to obtain methylene linked phenolic oligomers. In some embodiments, resoles may be formed using alkaline catalysts and a molar ratio of formaldehyde to phenol greater than 1 to obtain phenolic oligomers with methylene and benzyl ether linked phenolic units. In one or more embodiments, the polyurea resins include elastomeric polymers with carbamide (-NH-CO-NH-) linkages, which may be made by combining diisocyanate monomers or prepolymers with a blend of long chain amine terminated polyether or polyester resins and short chain diamine extenders. In one or more embodiments, polyurethane resins include polyurethane prepolymers with carbamate linkages that can be linear and elastomeric, formed by combining diisocyanates with long chain diols, or crosslinked and rigid, when formed from a combination of polyisocyanates and polyols. In one or more embodiments, vinyl ester resins include those formed by the addition reaction between epoxy resins, derivatives of acrylic acid, such as methacrylic acid, and vinyl functional monomers, such as styrene. In some embodiments, vinyl ester resins have high adhesion, heat and corrosion resistance, and may be stronger than polyesters and more impact resistant than epoxies.
[0076] In one or more embodiments, silicone resins are partially organic in nature, with a main chain polymer structure in which silicon and oxygen atoms alternate.In some embodiments, in addition to having at least one oxygen atom bonded to each silicone atom, silicone resins may have direct bonds with carbon, and are therefore known as polyorganosiloxanes.In some embodiments, they are represented by the general formula (RSiO)n and their physical form (liquid, gel, elastomer or solid), and their uses vary according to the molecular weight, structure (linear, branched, cage) and nature of the substituents (R = alkyl, aryl, H, OH, alkoxy). In some embodiments, aryl substituted silicone resins may have higher thermal stability than alkyl substituted silicone resins when polymerized (condensation cure mechanism) at temperatures between about 300°F (about 150°C) and about 400°F (about 200°C). When heated above about 600°F (about 300°C), the organic components thermally decompose to form compounds of the general formula (-SiO2-) n The silicone polymer may be transformed into a ceramic, leaving behind a crystalline silicate polymer having the desired properties. In some embodiments, silicone resins in the form of polysiloxane polymers made from silicone resins with pendant acrylate, vinyl ether or epoxy functional groups find use as UV, e-beam and thermosetting polymer matrix composites characterized by resistance to oxidation, heat and UV degradation.
[0077] In one or more embodiments, epoxy resins (also referred to herein as epoxy-functional monomers) are well-known reactive monomers and / or prepolymers that contain epoxide functional groups and react to form epoxy-based coatings. Generally, epoxy resins react with curing agents via a polymerization / crosslinking reaction to form solid epoxy-based coatings on the surface of a substrate. Epoxy resins can be reacted (e.g., "crosslinked" or "cured") with a wide range of curing agents, including acids (and anhydrides), phenols, alcohols, thiols, multifunctional amines, amides, or combinations thereof. Epoxy-based coatings are generally formulated based on the performance requirements of the final product. Epoxy resins, when properly catalyzed and applied, produce a hard, chemically resistant, solvent-resistant finish. The specific selection and combination of epoxy resins and curing agents, as well as any additionally added components (which may be referred to as additives), determine the final properties of the epoxy-based coating and its suitability for a given environment. Epoxy-based coatings can be used in a wide range of applications, including metal coatings, use in electronics / electrical components / LEDs, high voltage electrical insulation, paint brush manufacturing, fiber reinforced plastic materials, and structural adhesives.
[0078] In one or more embodiments, the present disclosure provides a composition (also known as a pre-cured composition) that can be used to form an epoxy-based coating, the composition comprising a solvent-based monomer comprising an epoxy-functional monomer. In one or more embodiments, the solvent-based monomer comprises a solvent-based epoxy resin. The epoxy-functional monomer or epoxy resin provides the main film-forming component and thus provides the base for forming the epoxy-based coating, and includes one or a combination of liquid monomers or prepolymers that contain epoxide functionality.
[0079] In one or more embodiments of the present disclosure, the epoxy-functional monomer (also known as an epoxy resin) comprises, consists essentially of, or consists of reaction products of epichlorohydrin with one or more of hydroxyl-functional aromatic compounds, alcohols, thiols, acids, acid anhydrides, cycloaliphatic and aliphatic compounds, polyfunctional amines, and amine-functional aromatic compounds; reaction products of the oxidation of unsaturated cycloaliphatic compounds; bisphenol diglycidyl ethers; epoxy-functional monomers modified with cycloaliphatic polyglycidyl ethers; epoxy-functional monomers modified with aliphatic glycidyl ethers; epoxy-functional epoxide siloxane monomers; or combinations thereof.
[0080] In one or more embodiments, the epoxy functional monomer (also known as an epoxy resin) comprises, consists essentially of, or consists of a bisphenol diglycidyl ether, an epoxy functional monomer modified with a cycloaliphatic polyglycidyl ether, an epoxy functional monomer modified with an aliphatic glycidyl ether, an epoxy functional epoxide siloxane monomer, or a combination thereof. In some embodiments, the bisphenol diglycidyl ether is derived from bisphenol A, bisphenol F, or a combination thereof. In some embodiments, the bisphenol diglycidyl ether is derived from bisphenol S, bisphenol A, bisphenol F, or a combination thereof.
[0081] In one or more embodiments, the epoxy functional monomer comprises an epoxy functional epoxide siloxane monomer (also referred to herein as a hybrid epoxy siloxane resin). The hybrid epoxy siloxane resin is also referred to herein as a hybrid epoxy polysiloxane resin, a silicone epoxy hybrid resin, or a siloxane modified hybrid epoxy resin. The epoxy functional epoxide siloxane monomer can be formed from an epoxy functional monomer and a siloxane / silicone monomer, prepolymer, or resin, or a system of such monomers, prepolymers, or resins, which react and covalently bond to form an intermediate molecular weight monomer that can be further polymerized through reactive epoxy and / or siloxane groups to form a cured coating. In one or more embodiments, the epoxy functional epoxide siloxane monomer is not formed from a physical mixture of prepolymerized epoxy and silicone resins. In one or more embodiments, the epoxy-functional epoxide siloxane monomer is not formed from a physical mixture of a pre-polymerized epoxy resin and a silicone resin that includes a coupling agent (e.g., a silane coupling agent) or other agent to promote miscibility of the epoxy resin with the silicone resin.
[0082] In one or more embodiments, the epoxy-functional epoxide siloxane monomer (also referred to herein as a hybrid epoxy siloxane resin) comprises an epoxy backbone with at least one siloxane or polysiloxane side chain. In some embodiments, the epoxy-functional epoxide siloxane monomer comprises an epoxy-functional epoxide (e.g., ether-linked) backbone with a siloxane or polysiloxane side chain. In some embodiments, the epoxy-functional epoxide siloxane monomer comprises an epoxy backbone with linear, branched, or crosslinked siloxane or polysiloxane side chains. In some embodiments, each siloxane or polysiloxane side chain has a linear, branched, or crosslinked three-dimensional structure. In some embodiments, the siloxane side chain is functionalized with an epoxy group, an alkoxy group, a hydroxyl group, or a hydroxyalkyl group. In some embodiments, the epoxy-functional epoxide siloxane monomer comprises an epoxy-functional epoxide backbone with siloxane or polysiloxane side chains functionalized with alkoxy groups, at least one of the side chains constituting a crosslinked three-dimensional structure. In some embodiments, at least one of the side chains comprising the crosslinked three-dimensional structure is a crosslinked silicone resin. In one or more embodiments, the siloxane or polysiloxane side chains may comprise from about 20% to about 50% of the molecular weight of the monomer. In some embodiments, the epoxy-functional epoxide siloxane monomer is a product of a polymer-like reaction comprising an isocyanate oligomer, a silane oligomer, and an epoxy oligomer. In some embodiments, the epoxy-functional epoxide siloxane monomer is a product of a polymer-like reaction comprising a polyurethane oligomer, a silane oligomer, and an epoxy oligomer.In some embodiments, the epoxy-functional epoxide siloxane monomer comprises one or a combination of 3-ethylcyclohexyl epoxy copolymer modified with dimethylsiloxane side chains, epoxy bisphenol A (2,2-bis(4'-glycidyloxyphenyl)propane) modified with polydimethylsiloxane side chains, a siloxane-modified hybrid epoxy resin, a silicone epoxide resin, or an epoxy-functional epoxide backbone functionalized with a crosslinked silicone resin containing terminal alkoxy groups. In some embodiments, the epoxy functional epoxide siloxane prepolymer comprises, consists essentially of, or consists of Silikopon® ED (silicone epoxide resins, also known as silicone epoxy resins, having an epoxy functional epoxide backbone functionalized with crosslinked silicone resins having terminal alkoxy groups), Silikopon® EF (silicone epoxide resins, also known as silicone epoxy resins, having an epoxy functional epoxy backbone functionalized with crosslinked silicone resins having terminal alkoxy groups, Silikopon® EF may have fewer terminal alkoxy groups than Silikopon® ED), EPOSIL Resin 5550® (siloxane modified hybrid epoxy resin), or combinations thereof.
[0083] The type and amount of solvent-based monomer selected for use in the pre-cured composition will depend, in part, on the performance requirements of the epoxy-based coating and / or the type of surface or substrate onto which the coating is formed.
[0084] Polyurea or polyurethane resins can be selected when it is desired that the cured coating has elastomeric properties. Vinyl ester resins can be selected when higher adhesion, heat resistance, corrosion resistance, and mechanical strength are desired compared to polyesters, or higher impact resistance is desired compared to epoxies. Silicone resins such as aryl-substituted silicone resins can be selected for higher thermal stability compared to alkyl-substituted silicone resins, and silicone resins in the form of polysiloxane polymers made from silicone resins with pendant acrylate, vinyl ether, or epoxy functional groups can be selected for use as UV, e-beam, and thermosetting polymer matrix composites for their resistance to oxidation, heat, and UV degradation.
[0085] In general, epoxy functional monomers (also referred to herein as epoxy resins derived from bisphenol A and bisphenol F) are considered equivalents that provide coatings with similar properties. Furthermore, epoxy functional monomers derived from bisphenol A and bisphenol F can be used in blends (mixtures of bisphenol A and F) or as hybrids (one molecule containing both bisphenol A and F components). In some embodiments, epoxy functional monomers derived from bisphenol A can be selected to reduce costs, as they are often less expensive than bisphenol F. In other embodiments, epoxy functional monomers derived from bisphenol F can be selected to impart higher corrosion resistance to the cured epoxy-based coating, as coatings formed from bisphenol F are generally known to be more corrosion resistant than those formed from bisphenol A. Furthermore, epoxy functional monomers derived from bisphenol F can be selected when it is desired that the cured epoxy-based coating is food safe. Since bisphenol F generally has a lower viscosity than bisphenol A, epoxy functional monomers derived from bisphenol F can be selected when it is desired to use less diluent. Epoxy-functional monomers derived from bisphenol F may be selected when it is desired that the cured epoxy-based coating have reduced biotoxicity.
[0086] The selection of one or more of the epoxy-functional epoxide siloxane monomers (also referred to herein as hybrid epoxy siloxane resins) can enhance the durability of the cured epoxy-based coating compared to silicone oil-containing coatings (e.g., soft fouling release coatings). The selection of the epoxy-functional epoxide siloxane monomers can enhance the heat resistance of the cured epoxy-based coating or contribute to the antifouling / fouling release properties of the cured coating.
[0087] Generally, when it is desired that the composition contain about 80% to about 90% solids by weight, a solvent-based monomer having a lower viscosity, such as in the range of about 200 cps to about 1500 cps, can be selected. In some embodiments, the selection of a low viscosity solvent-based monomer allows the processability of compositions containing high loadings of ceramic performance additives, such as hollow ceramic spheres, to be maintained without the need to add large amounts of solvent or diluent to maintain a processable viscosity of about 3500 cps or less. In some embodiments, the low viscosity solvent-based monomer comprises an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 350 to about 550 cps, an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 400 to about 1000 cps, an epoxy-functional monomer modified with an aliphatic glycidyl ether having a viscosity in the range of about 800 to about 1000 cps, or a combination thereof. In some embodiments, the low viscosity solvent-based monomer comprises a low viscosity epoxy resin comprising an epoxy resin having a viscosity (MPa·s) of about 200 to about 7000, or about 350 to about 6500 at 25° C. In some embodiments, the low viscosity solvent-based monomer comprises DLVE®-52 (ultra-low viscosity epoxy resin modified with alicyclic polyglycidyl ether epoxy resin), DLVE®-18 (low viscosity epoxy resin modified with alicyclic polyglycidyl ether epoxy resin), DER® 353 (C12-C14 aliphatic glycidyl ether modified bisphenol A / F epoxy resin), or a combination thereof.
[0088] In some embodiments, a solvent-based monomer (also known as a solvent-based epoxy resin) having a viscosity greater than about 1500 cps, such as about 10,000 to 20,000 cps, can be selected when the composition is suitable for containing less than about 80% to about 90% by weight solids, or when larger amounts of diluent or solvent are used, such that the mixture of solvent-based monomer and diluent has a viscosity in a range low enough to maintain processability of the composition with high loadings of hollow ceramic spheres, such as a viscosity in the range of about 200 to about 3500 cps, or about 300 to about 3500 cps.
[0089] In one or more embodiments, the solvent-based monomer is present in the pre-cured composition in a range of about 5% to about 40% by weight, or any range of weight percents between about 5% to about 40% by weight. In some embodiments, the epoxy functional monomer comprises about 5% to about 35% by weight of the pre-cured composition. In other embodiments, the epoxy functional monomer comprises about 5% to about 30% by weight of the pre-cured composition. In one or more embodiments, the solvent-based epoxy resin is present in the pre-cured composition in an amount of about 5 to about 30% by weight, about 5 to about 20% by weight, or about 15 to about 20% by weight, based on the weight percent of Part A, or any range of weight percents between about 5% to about 30% by weight. In one or more embodiments, the solvent-based epoxy resin comprises a hybrid epoxy siloxane resin and is present in the pre-cured composition in an amount of about 30 to about 55 weight percent, or about 40 to about 50 weight percent, based on the weight percent of Part A, or any weight percent, or any weight percent range from about 30 weight percent to about 55 weight percent.
[0090] Ceramic Performance Additives
[0091] As mentioned above, one or more embodiments of the present disclosure provide a pre-cured composition comprising a solvent-based resin, a diluent, an adhesion promoter, a rheology modifier, and a ceramic performance additive. In one or more embodiments, the ceramic performance additive is added to the composition to enhance the sound deadening properties of the cured coating, or the ceramic performance additive is added to the composition to increase the hardness (measured by scratch resistance) of the cured coating, or a combination thereof (compared to a control). In one or more embodiments, when the ceramic performance additive is added to the composition to enhance scratch resistance by increasing hardness, the ceramic performance additive can also be used to enhance cavitation resistance. The harder and more scratch resistant the cured coating is, the less damage the coating can sustain, thereby reducing the occurrence or number of pits, scratches, erosion sites, dents, or other forms of damage that can cause cavitation.
[0092] In one or more embodiments, the ceramic performance additive includes hollow ceramics and non-hollow ceramics.
[0093] Hollow ceramic. In one or more embodiments, the hollow ceramic comprises hollow ceramic spheres. The hollow ceramic spheres may have a shape that is spherical, substantially spherical, spherical-like, spheroidal, substantially spheroidal, spheroidal, or a combination thereof. As described above, one or more embodiments of the present disclosure provide a pre-cured composition that includes a solvent-based monomer, a diluent, an adhesion promoter, and hollow ceramic spheres. In one or more embodiments, the inclusion of hollow ceramic spheres in the composition improves sound deadening properties (compared to a control) and / or improves hardness of the cured coating.
[0094] In one or more embodiments, hollow ceramic spheres can provide sound deadening properties due to their size, hollow core, ceramic composition, and / or loading rate in the composition. In some embodiments, the hollow ceramic spheres comprise a particle size of about 20 μm to about 40 μm, or about 30 μm to about 40 μm, or about 35 μm. In some embodiments, the hollow ceramic spheres can be present in the pre-cured composition in a range of about 30% to about 70% by weight (about 15% to about 55% by volume, based on a density of about 1 to about 3, or about 2 to about 2.5). With reference to Example 1, it has been found that the use of hollow ceramic spheres in the present compositions (i) provides improved absolute noise reduction (decibels, dB) compared to hollow glass spheres of equal or larger size and / or equal loading rate, (ii) provides improved absolute noise reduction (decibels, dB) compared to mixtures of hollow ceramic spheres with other purported noise suppression additives, such as hollow glass spheres and / or finely divided barium sulfate, and (iii) provides improved absolute noise reduction (decibels, dB) compared to hollow ceramic spheres of smaller particle size, such as about 12 μm. Without wishing to be bound by theory, hollow ceramic spheres having a particle size of about 20 μm to about 40 μm, at loadings of about 30% to about 70% by weight (about 15% to about 55% by volume), can at least provide a sufficient concentration of air-filled voids in the cured coating to improve sound deadening properties and / or at least destructively (or reflectively) interfere with radiated sound waves to improve sound deadening properties.
[0095] In some embodiments, the hollow ceramic spheres may be present in the pre-cured composition in a range of about 20% to about 40% by weight, or about 25% to about 35% by weight, based on the weight percent or total weight percent of Part A. With reference to Example 2, it has been found that the use of hollow ceramic spheres in the compositions of the present invention (i) improves absolute noise reduction (decibels, dB) compared to coating compositions that do not contain hollow ceramic spheres, (ii) improves absolute noise reduction (decibels, dB) compared to hollow glass spheres of comparable or smaller size and / or comparable loading rate, and (iii) improves absolute noise reduction (decibels, dB) by up to about 10 dB at cured coating thicknesses between 250 micrometers and 275 micrometers. With reference to Example 2, it has also been found that in at least some examples of the present compositions, the use of hollow ceramic spheres in an amount of at least 45% by weight (based on the weight percent of Part A) results in a cured coating with reduced impermeability to water. Without wishing to be bound by theory, it was believed that increasing the amount of spheres may impede cohesiveness and / or complete film formation as the resin cures, which may result in weak spots in the coating that are more susceptible to damage or less obstructed pathways in the coating through which water can pass.
[0096] In one or more embodiments, where hollow ceramic spheres are added to the composition to improve the sound deadening properties of the cured coating, the resulting cured coating may be applied to a substrate as an undercoat. In some embodiments, the hollow ceramic spheres also increase the hardness or scratch resistance of the cured undercoat. In some embodiments, the hardness may be increased to at least 5H, as measured according to ASTM D3363.
[0097] In some embodiments, when hollow ceramic spheres are added to the composition to improve the sound deadening properties of the cured coating, a topcoat can be applied over the resulting cured coating. In some embodiments, the loading rate of hollow ceramic spheres is high enough that the resulting cured coating has a rough and uneven surface. Such surfaces can be susceptible to fouling, so a topcoat can be applied to reduce fouling. In some embodiments, the applied topcoat can be selected to provide antifouling / fouling release properties or other desired properties consistent with the end use of the coating and / or the substrate to which it is applied. In one or more embodiments, the topcoat applied to the cured undercoat may include a coating as described in International Application No. PCT / CA2021 / 000042, entitled "Composition For A Coating, Coatings and Methods Thereof," which claims priority to U.S. Provisional Application No. 63 / 024,447, or International Application No. PCT / CA2019 / 050334, entitled "Multifunctional Coatings for Use in Wet Environments," which claims priority to U.S. Provisional Application No. 62 / 645,504, each of which is incorporated herein by reference.
[0098] In one or more embodiments, the addition of hollow ceramic spheres to the composition increases the hardness (or as indicated by scratch resistance) of the cured coating. In some embodiments, the hollow ceramic spheres can provide improved hardness properties due to their size, hollow center, composition, and / or loading rate in the composition. In some embodiments, the hollow ceramic spheres comprise a particle size of about 10 μm to about 40 μm. In some embodiments, the hollow ceramic spheres comprise a particle size of about 10 μm to about 15 μm. In some embodiments, the hollow ceramic spheres can be present in the composition in a range of about 5% to about 20% by weight (about 3% to about 20% by volume, based on a density of about 1 to about 3, or about 2 to about 2.5). In some embodiments, the hollow ceramic spheres are present in the composition in a range of about 5% to about 15% by weight, based on the weight percent of Part A. Without wishing to be bound by theory, the use of hollow ceramic spheres having a particle size of about 10 μm to about 15 μm at a loading of about 5% to about 20% by weight (about 3% to about 20% by volume), or hollow ceramic spheres having a particle size of about 10 μm to about 40 μm at a loading of about 5% to about 15% by weight, may at least improve scratch resistance, which is due to the loading rate, which can provide the ceramic spheres' high hardness (e.g., 7 on the Mohs scale), in some embodiments, their smaller size (e.g., about 12 μm), or a relatively smooth surface. In one or more embodiments, when the addition of hollow ceramic spheres to the composition improves the scratch resistance of the cured coating, the resulting cured coating can be applied to a substrate as a topcoat and further formulated to provide anti-fouling / foul release properties or other desired properties consistent with the end use of the coating and / or the substrate to which it is applied.
[0099] In one or more embodiments, the hollow ceramic spheres include spheres having a particle size of about 20 μm to about 40 μm, or about 25 μm to about 35 μm. In some embodiments, the hollow ceramic spheres are present at a weight percent loading ranging from about 20 wt % to about 40 wt %, or about 25 wt % to about 35 wt %, based on the weight % or total weight % of Part A. In some embodiments, the hollow ceramic spheres are present at a weight percent loading ranging from about 30 wt % to about 70 wt %, or about 35 wt % to about 65 wt %, or about 30 wt % to about 50 wt %, or about 35 wt % to about 50 wt %, or about 45 wt % to about 70 wt %, or about 50 wt % to about 65 wt %. In some embodiments, the hollow ceramic spheres include Zeeospheres® G 600 hollow ceramic spheres, W410® hollow ceramic spheres, W610® hollow ceramic spheres, or combinations thereof.
[0100] In one or more embodiments, the hollow ceramic spheres include spheres having a particle size of about 10 μm to about 40 μm, about 20 μm to about 40 μm, or about 25 μm to about 35 μm, or about 10 μm to about 15 μm, or about 12 μm. In one or more embodiments, the hollow ceramic spheres include spheres having a particle size of about 10 μm to about 15 μm, or about 12 μm. In some embodiments, the hollow ceramic spheres are present in a weight percent loading ranging from about 5 wt % to about 15 wt %, based on the weight % or total weight % of Part A. In some embodiments, the hollow ceramic spheres are present in a weight percent loading ranging from about 5 wt % to about 20 wt %, or about 10 wt % to about 20 wt %, or about 10 wt % to about 18 wt %, or about 10 wt % to about 15 wt %. In some embodiments, the hollow ceramic spheres include Zeeospheres® N-200PC hollow ceramic spheres, W210® hollow ceramic spheres, or a combination thereof.
[0101] Non-hollow ceramic. In one or more embodiments, the non-hollow ceramic comprises non-hollow ceramic particles. In one or more embodiments, the addition of non-hollow ceramic particles to the composition increases the hardness (alternatively as measured by scratch resistance) of the cured coating. In one or more embodiments, where the addition of non-hollow ceramic particles to the composition increases scratch resistance by increasing hardness, the use of non-hollow ceramic particles can also increase cavitation resistance. Without wishing to be bound by theory, the use of non-hollow ceramic particles may at least improve scratch and abrasion resistance, and thus cavitation resistance, due to the hardness of the ceramic particles, small particle size, and / or loading rate, which can provide a relatively smooth surface. As stated above, the harder and more scratch resistant the cured coating is, the less damage the coating can sustain, thereby reducing the occurrence or number of pits, scratches, dents, erosion sites, or other forms of damage that could otherwise result in cavitation. In one or more embodiments, the non-hollow ceramic particles have a hardness of from about 5 to about 10, or from about 7 to about 9 on the Mohs scale.
[0102] In one or more embodiments, the non-hollow ceramic particles comprise a particle size of about 0.1 μm to about 5 μm, about 0.5 μm to about 5 μm, or about 1 μm to about 5 μm, or about 2 μm to about 5 μm. In one or more embodiments, the non-hollow ceramic particles are present in the composition in a range of about 10 wt% to about 50 wt%, or about 10 wt% to about 45 wt%, or about 15 wt% to about 40 wt%, based on the weight of Part A. In one or more embodiments, the non-hollow ceramic particles are present in the composition in a range of about 5 wt% to about 40 wt%, or about 10 wt% to about 35 wt%, or about 20 wt% to about 35 wt%, or about 10 wt% to about 20 wt%, based on the weight % or total weight % of Part A.
[0103] In one or more embodiments, the non-hollow ceramic particles include titanium oxide, fumed silica, brown aluminum oxide (III), fused aluminum oxide (III), titanium alloy, or combinations thereof. In some embodiments, the titanium alloy includes titanium carbonitride, titanium carbide, or combinations thereof. In some embodiments, the titanium oxide and / or fumed silica may further include anti-wear, anti-abrasion properties and therefore act as anti-wear additives as described herein. In some embodiments, the fumed silica may further include rheology modifying properties and therefore act as rheology modifiers as described herein. Fumed aluminum oxide (III) has a slightly lighter density (3.8 vs. 4) and a relatively higher oil absorption rate compared to brown aluminum oxide (III). In one or more embodiments, fused aluminum oxide (III) may be less prone to settling, act as a rheology modifier, and / or improve the long-term stability (e.g., shelf life) of the pre-cured composition. The type and amount of non-hollow ceramic particles selected for use in the pre-cured composition depends, in part, on the performance requirements of the cured coating. Thus, the non-hollow ceramic particles can be selected based on hardness characteristics as well as other properties such as anti-wear properties, rheology modifying properties, and / or shelf life.
[0104] In one or more embodiments, where the scratch resistance of the cured coating is improved by adding non-hollow ceramic particles to the composition, the resulting cured coating can be applied to a substrate as a topcoat and further formulated to provide anti-fouling / foul release properties or other desired properties compatible with the end use of the coating and / or the substrate to which the coating is applied.
[0105] In one or more embodiments, the ceramic performance additive is included in an amount sufficient to provide a coating formed from the composition having a reduced noise emission of about 2 dB to about 10 dB per about 100 μm of coating thickness at frequencies from about 10 Hz to about 10 kHz as measured on a 3 mm thick cold rolled steel sheet compared to a 3 mm thick cold rolled steel sheet coated with a coating without the ceramic performance additive. In one or more embodiments, the ceramic performance additive is included in an amount sufficient to provide a coating formed from the composition having a reduced noise emission of about 3 dB to about 9 dB, about 5 dB to about 9 dB, or about 5 dB to about 7 dB per about 100 μm of coating thickness as measured on a 3 mm thick cold rolled steel sheet coated with a coating without the ceramic performance additive.
[0106] In one or more embodiments, the ceramic performance additive is included in an amount sufficient to provide a coating formed from the composition having a hardness of at least 5H as measured according to ASTM D3363. In one or more embodiments, the ceramic performance additive is included in an amount sufficient to provide a coating formed from the composition having a hardness of from about 6H to about 8H, or about 8H.
[0107] In one or more embodiments, the ceramic performance additive, such as hollow ceramic spheres, are included in an amount sufficient to provide a coating formed from the composition having reduced noise emissions (e.g., sound deadening properties) of about 1 dB to about 50 dB per about 100 μm coating thickness at frequencies of about 1000 Hz or less, or a hardness of at least 5H as measured according to ASTM D3363, as compared to an uncoated 3 mm thick steel plate. In one or more embodiments, the hollow ceramic spheres are included in an amount sufficient to provide a coating formed from the composition having reduced noise emissions of about 1 dB to about 20 dB, or about 15 dB, per about 100 μm coating thickness, or a hardness of about 6H to about 8H for noise in the range of about 100 to about 1000 Hz, or about 100 to about 400 Hz.
[0108] Adhesion promoter
[0109] As mentioned above, one or more embodiments of the present disclosure provide a pre-cured composition comprising a solvent-based monomer, a diluent, and an adhesion promoter. In one or more embodiments, the inclusion of an adhesion promoter in the composition improves the flexibility of the cured coating obtained from the composition, e.g., as measured by a cylindrical bend test, as indicated by a flexural strength of at least 10 mm. In one or more embodiments, when the cured coating is applied as an undercoat, the inclusion of an adhesion promoter can improve the intercoat or recoat adhesion between the cured undercoat and any topcoat that may be applied. In one or more embodiments, when the cured coating is applied to a primed substrate (e.g., a substrate that includes a primer coating), the inclusion of an adhesion promoter can improve the overcoat adhesion between the cured coating and the primed substrate. In one or more embodiments, when the cured coating is applied directly to a substrate, the inclusion of an adhesion promoter can improve the substrate adhesion between the cured coating and the substrate.
[0110] In one or more embodiments, the adhesion promoter in combination with the curing agent composition can increase the adhesion of the cured coating to a metal substrate or a primed metal substrate (see, e.g., Curing Agents below). In one or more embodiments, the adhesion promoter in combination with a wear inhibitor such as graphite oxide, graphene, multi-layer graphene flakes, etc. can improve flexural strength.
[0111] In one or more embodiments, the adhesion promoter is included in an amount sufficient to provide a coating formed from the composition having an intercoat adhesion (also known as recoat adhesion or recoat adhesion window) of at least 5 MPa as measured according to ASTM D4541, or a flexural strength of at least 10 mm as measured in a cylindrical bend test. In one or more embodiments, the adhesion promoter is included in an amount sufficient to provide a coating formed from the composition having an intercoat adhesion of about 5 MPa to about 10 MPa as measured according to ASTM D4541, or a flexural strength of at least 8 mm or about 6 mm as measured in a cylindrical bend test.
[0112] In one or more embodiments, the adhesion promoter is included in an amount sufficient to provide a coating formed from the composition having a substrate adhesion of at least 3 MPa, as measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa, as measured according to ASTM D4541, or a recoat adhesion window of at least 4 hours, as measured according to ASTM D3359.
[0113] In one or more embodiments, when an adhesion promoter is included in the pre-cured composition, a coating formed from the composition has a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541; an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541; a recoat adhesion window of about 4 hours to about 72 hours, as measured according to ASTM D3359; or a combination thereof.
[0114] In one or more embodiments, when an adhesion promoter is included in the pre-cured composition, a coating formed from the composition has a substrate adhesion of at least 3 MPa as measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa as measured according to ASTM D4541, or a combination thereof. In one or more embodiments, when an adhesion promoter is included in the pre-cured composition, a coating formed from the composition has a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, or about 3 MPa to about 7 MPa, or about 5 MPa to about 7 MPa as measured according to ASTM D4541, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, or about 3 MPa to about 7 MPa, or about 5 MPa to about 7 MPa as measured according to ASTM D4541, or a combination thereof.
[0115] The adhesion promoter can improve the flexibility and / or intercoat / recoat adhesion of the cured coating formed from the composition due to the reactive groups of the promoter. In one or more embodiments, the adhesion promoter has at least two, or at least three functional groups that can couple to ceramic performance additives, such as hollow ceramic spheres or non-hollow ceramics, and / or can be incorporated into the polymerization of solvent-based monomers. In one or more embodiments, the adhesion promoter can act as a binder between the ceramic performance additives, such as hollow ceramic spheres, and the solvent-based resin of the pre-cured composition to improve the flexibility of the cured coating containing the hollow ceramic spheres. In some embodiments, the adhesion promoter can improve the cohesion of the cured coating containing the ceramic performance additives, such as hollow ceramic spheres. Cohesion here refers to the mechanical strength of a single cured coating layer, and how well it resists peeling, compressive, bending, or any other damaging forces. In one or more embodiments, when the cured coating is applied as an undercoat, the adhesion promoter can act as a binder between the cured undercoat and any topcoat that may be applied to improve the intercoat adhesion.
[0116] In one or more embodiments, the adhesion promoter is a silane. In one or more embodiments, the adhesion promoter is a functionalized silane. In some embodiments, the functionalized silane comprises two or three alkoxy (OR) reactive groups. In some embodiments, the functionalized silane comprises a functional group that is reactive in the polymerization of a solvent-based monomer, such as an epoxy functional group or an amino functional group, or a combination thereof. Without wishing to be bound by theory, in embodiments where the adhesion promoter is a silane, the silane can improve the flexibility and / or intercoat adhesion of the cured coating due to the alkoxy groups of the silane being able to form siloxane (Si-O-Si) bonds by reaction with surface hydroxyl groups on the substrate or hollow ceramic spheres, or to be incorporated in the polymerization of a solvent-based monomer. Without wishing to be bound by theory, in embodiments where the adhesion promoter is a silane, the silane can improve the wet adhesion, hydrophobicity, and / or corrosion protection of the cured coating. For example, the adhesion promoting silane can be activated by acid and / or moisture on the surface of the substrate or on the surface of the hollow sphere to form silanol (Si-OH) groups that can react with surface hydroxyl (OH) groups via a condensation reaction (e.g., Si-OH+HO⇒substrate Si-Osubstrate). Additionally, the adhesion promoting silane can be incorporated into the polymerization of a solvent-based monomer by reacting with the solvent-based monomer and / or curing agent. In one or more embodiments, the adhesion promoter comprises a weathering additive as described herein. In one or more embodiments, the adhesion promoter comprises a silamine curing agent triamino-functional propyltrimethoxysilane as described herein.
[0117] In one or more embodiments, the adhesion promoter is 3-(2,3-epoxypropoxy)propyltrimethoxysilane, glycidoxypropyltrimethoxysilane (e.g., Andisil 187®), aminopropyltriethoxysilane, 3-aminopropyltriethoxysilane, secondary aminobissilanes (e.g., Silquest* A-1170®, Andisil 1100®, Dynasylan Ameo®), triaminofunctional propyltrimethoxysilane (Dynasylan TRIAMO (Evonik)), or combinations thereof. In one or more embodiments, the adhesion promoter is present in the pre-cured composition in any weight percent range of about 0.1% to about 5% by weight, or about 0.1% to about 1% by weight, or about 1% to about 5% by weight, or 0.1% to about 5% by weight.
[0118] In one or more embodiments, an adhesion promoter is included in the pre-cured composition to improve adhesion of the cured coating to a metal substrate or a primed metal substrate. In one or more embodiments, when the curable coating is applied directly to a metal substrate, an adhesion promoter can be included to improve substrate adhesion between the cured coating and the metal substrate. In one or more embodiments, when the cured coating is applied to a primed metal substrate, an adhesion promoter can be included in both the primer composition and the coating composition to improve substrate adhesion between the cured coating and the primed metal substrate. The metal substrate can be a steel substrate, a copper substrate, a copper alloy substrate, or other metal substrate.
[0119] In one or more embodiments, the adhesion promoter comprises a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof. The dry adhesion promoter, the dry / wet adhesion promoter, and / or the wet adhesion promoter may be non-reactive, reactive in epoxy polymerization, reactive with metal substrates, and / or reactive with surface oxides on metal substrates, or combinations thereof. The type and amount of adhesion promoter selected for use in the pre-cured composition depends, in part, on the performance requirements of the cured coating, the type of adhesion being promoted, and / or the mechanism of adhesion desired.
[0120] In one or more embodiments, the dry adhesion promoter is non-reactive, reactive in epoxy polymerization, reactive with the substrate, and / or reactive with metal oxides. In one or more embodiments, the dry adhesion promoter may include one or more functional groups capable of reacting with inorganic surfaces (e.g., surface oxides on ceramic, metal substrates). The dry adhesion promoter may also include one or more functional groups that are reactive in epoxide polymerization and capable of reacting with solvent-based epoxy resins, thereby enhancing the adhesion of the resulting coating to metal substrates (e.g., Cu substrates). In one or more embodiments, the dry adhesion promoter includes an alkoxylated silane. The organofunctional silane includes at least two different reactive groups so that it can react and bond with inorganic surfaces (e.g., surface oxide layers on ceramic and metal substrates). When the organofunctional silane includes an amine functional group, the silane can co-react with the epoxy resin to promote adhesion to metal substrates, such as Cu substrates. Such dry silane promoters may also contribute to the overall hydrophobic properties of the coating. In one or more embodiments, the dry adhesion promoter comprises glycidoxypropyltrimethoxysilane (e.g., Andisil 187®), aminopropyltriethoxysilane (e.g., Andisil 1100®), triaminofunctional propyltrimethoxysilane (e.g., Dynasylan TRIAMO (Evonik)), or combinations thereof. In one or more embodiments, the dry adhesion promoter is present in the pre-cured composition in a range of about 1 wt % to about 10 wt %, or about 1 wt % to about 8 wt %, or any weight % or weight % range of 1 wt % to about 10 wt %, based on the weight % or total weight % of Part A.
[0121] In one or more embodiments, the wet adhesion promoter is reactive with metal substrates. In one or more embodiments, the wet adhesion promoter may be activated in a wet environment by decomposing in the presence of ions in water that permeates the coating. The decomposition products may react with metal substrates, such as Cu alloys, and may also cross-react with undecomposed promoters. This may result in a strong bond between the coating layer and the metal substrate, and may also prevent corrosion of the substrate. In one or more embodiments, the wet adhesion promoter comprises a metal-doped phosphosilicate. In one or more embodiments, the wet adhesion promoter comprises a strontium phosphosilicate (e.g., HALOX® SW-111), a zinc calcium strontium aluminum orthophosphate silicate hydrate (e.g., HEUCOPHOS® ZCP-Plus), a zinc phosphosilicate (e.g., InvoCor CI-3315), or a combination thereof. In one or more embodiments, the wet adhesion promoter is present in the pre-cured composition in the range of about 1 wt % to about 5 wt %, or any wt % or wt % range between 1 wt % and about 5 wt %, based on the wt % or total wt % of Part A.
[0122] In one or more embodiments, the dry / wet adhesion promoter is non-reactive, reactive with the substrate, and / or reactive with metal oxides. In one or more embodiments, the dry / wet adhesion promoter can provide good flow properties that help the curable coating flow into rough areas on the metal substrate, which can facilitate the formation of a grip between the cured coating and the substrate. In one or more embodiments, the dry / wet adhesion promoter can include one or more functional groups that can react with the metal substrate. The dry / wet adhesion promoter can also include one or more functional groups that are reactive in epoxide polymerization and can react with solvent-based epoxy resins. In one or more embodiments, the dry / wet adhesion promoter includes modified polyesters, modified polyester oligomers, polyacrylic acids, polyacrylates, benzotriazoles, polymers or prepolymers containing mercaptans, hydroxyphenyl-benzotriazoles, hydroxyphenyl-triazines, or combinations thereof. In one or more embodiments, the dry / wet adhesion promoter comprises a modified polyester having sufficient hydroxyl number of about 30 mg to about 100 mg KOH / g, such as Tego Addbond LTW-B®, Tego Addbond 2220 ND®, which can provide good flow properties to help the curable coating flow into rough areas on the metal substrate, which can facilitate the formation of a grip between the cured coating and the substrate. In one or more embodiments, the dry / wet adhesion promoter comprises an alkyl-substituted hydroxylamine-substituted benzotriazole, such as CCI-01 copper adhesion promoter, where the benzotriazole of the curable coating can react with a metal substrate, such as copper, to form Cu-BTA, protecting the surface from corrosion and maintaining a strong grip between the coating and the substrate.In one or more embodiments, the dry / wet adhesion promoter comprises a polymer or prepolymer containing mercaptans, such as CAPCURE® 3-800, CAPCURE® 40 SEC HV, where the thiol can be oxidized to bond to substrates including copper, and the amine functionality (if present in the thiol compound) can co-react with epoxy resins to promote adhesion to metal substrates such as Cu substrates. In one or more embodiments, the dry / wet adhesion promoter is present in the pre-cured composition in a range of about 0.1 wt % to about 1 wt %, or any weight % or weight % range of 0.1 wt % to about 1 wt %, based on the weight % or total weight % of Part A.
[0123] Rheology Modifiers
[0124] As mentioned above, the present disclosure provides a pre-cured composition further comprising a rheology modifier. In one or more embodiments, the rheology modifier comprises an anti-settling rheology modifier, an anti-sag rheology modifier, an anti-crater surface leveling rheology modifier, or a combination thereof. The inclusion of a rheology modifier in the composition can at least reduce sagging of the curable composition when applied to a substrate, allow for more uniform application of the curable composition to the substrate, at least reduce settling of components or additives, and / or facilitate the formation of a cured coating with a more uniform surface (compared to a control). In one or more embodiments, the inclusion of a rheology modifier in the composition provides a curable composition with anti-settling, anti-sag, or surface leveling properties.
[0125] In one or more embodiments, the inclusion of a rheology modifier in the pre-cured composition adjusts the viscosity of the pre-cured composition and / or the curable composition. In one or more embodiments, the inclusion of a rheology modifier provides the curable composition with anti-sag properties. The rheology modifier can adjust the viscosity of the pre-cured and / or curable composition by increasing the viscosity such that sagging of the curable composition is at least reduced when the curable composition is applied to a surface or substrate (compared to a control). In some embodiments, the rheology modifier can adjust the viscosity of the pre-cured and / or curable composition by decreasing the viscosity such that the curable composition has a sufficiently low viscosity to be applied to a surface or substrate via brushing, rolling, spraying, etc. (compared to a control). In some embodiments, the rheology modifier adjusts the viscosity of the pre-cured and / or curable composition so that the curable composition may be applied to a surface or substrate by brushing, rolling, spraying, etc., while at least reducing sagging of the curable composition when the curable composition is applied to a surface or substrate, and at least reducing the formation of macroscopic defects and roughness, such as curtains, dripping, or other sagging-related defects (compared to a control). Such defects may occur in the absence of the rheology additive, and may result in increased roughness or reduced uniformity of the surface of the cured coating. Such defects may increase cavitation when the cured coating is applied to a substrate, such as a propeller. In some embodiments, the rheology modifier facilitates the formation of a cured coating with a more uniform surface by adjusting the viscosity of the pre-cured and / or curable composition, and at least reducing sagging when the curable composition is applied to a surface or substrate, and reducing the formation of macroscopic defects and roughness at the surface of the cured coating. Such defects may occur in the absence of the rheology additive, and may result in increased roughness or reduced uniformity of the surface of the cured coating.In some embodiments, the rheology modifier adjusts the viscosity of the pre-cured composition and / or the curable composition to promote a more uniform high-build application of the curable composition while reducing sagging when applied at a thickness of about 10 mils or more. High-build application refers to a thick application of the curable composition during the coating process. High-build application can be selected when a single application of the high-build composition is desired or required, rather than several successive applications, since a single application of the high-build composition can achieve the desired coating thickness without long waiting times and / or additional labor.
[0126] In some embodiments, the inclusion of a rheology modifier in the pre-cured composition enhances the thixotropic properties of the pre-cured or curable composition. In one or more embodiments, the inclusion of a rheology modifier provides the curable composition with anti-settling properties. Increasing the thixotropic properties of the pre-cured or curable composition can improve the processability and handling of the pre-cured or curable composition by making it easier to mix, stir, or apply the composition to a surface or substrate. In other embodiments, the inclusion of a rheology modifier in the pre-cured composition provides solid suspension. In some embodiments, the inclusion of a rheology modifier in the pre-cured composition enhances the shelf life, packaging stability, and / or anti-settling properties of the composition.
[0127] In one or more embodiments, a rheology modifier is included in the pre-curing composition to adjust the viscosity of the pre-curing composition and / or the curable composition when a relatively high loading rate (e.g., 30 wt.% or more) of hollow ceramic spheres is used in the pre-curing composition of the present disclosure, which promotes reduced sagging, uniform application, and / or the formation of a cured coating with a more uniform surface (compared to a control). The use of hollow ceramic spheres in the pre-curing composition thickens the composition, which may affect the application of the composition to a substrate. Furthermore, the use of hollow ceramic spheres in the pre-curing composition increases the weight or bulk of the composition after application to a substrate, which may cause the applied composition to sag, thereby affecting the ability to form a cured coating with a more uniform surface.
[0128] In one or more embodiments, the inclusion of a rheology modifier in the pre-cured composition improves the flow or wetting properties of the composition, such that when the curable composition of the present disclosure is applied, there is improved flow of the composition and / or improved wetting of the substrate. In one or more embodiments, the inclusion of a rheology modifier provides a curable composition with surface leveling properties. In one or more embodiments, improving the flow or wetting of the substrate can reduce or prevent defect formation in the cured coating. In some embodiments, the wetting can promote the formation of a smooth cured coating with reduced micro-level roughness. In one or more embodiments, the rheology modifier included to improve the flow or wetting properties of the composition includes a polyether siloxane copolymer, such as TEGO® Glide 410® (Evonik). In one or more embodiments, the polyether siloxane copolymer, such as TEGO® Glide 410® (Evonik), can also act as a dispersant.
[0129] The type and amount of rheology control agent selected for use in the pre-cured composition will depend, in part, on the performance requirements of the cured coating and / or the type of surface or substrate onto which the coating is formed.
[0130] In one or more embodiments, the inclusion of an anti-settling rheology modifier in the composition at least reduces settling of the ceramic performance additive in the composition or the curable composition. In one or more embodiments, the anti-settling rheology modifier comprises silica, clay, or a combination thereof. In one or more embodiments, the anti-settling rheology modifier comprises fumed silica, fumed silica surface modified with silane, fumed silica surface modified with dimethyldichlorosilane, aluminum phyllosilicate clay, organo-modified derivatives of aluminum phyllosilicate clay, organo-modified bentonite clay, organo-modified montmorillonite clay, or a combination thereof. In one or more embodiments, the anti-settling rheology modifier is present in the pre-cured composition in any weight percent or weight percent range of about 0.1 weight percent to about 5 weight percent, or about 0.3 weight percent to about 3 weight percent, or about 0.3 weight percent to about 2 weight percent, or about 0.1 weight percent to about 5 weight percent, based on the weight percent or total weight percent of Part A.
[0131] In one or more embodiments, fumed silica is formed by silica blown into a flame and partially melted. In one or more embodiments, fumed silica has a curved sheet-like structure. When added to a pre-cured composition, fumed silica and its modified forms tend to disperse, introducing a 3D-like structure into the volume of the composition and preventing components such as hard particles from settling and coalescing. In one or more embodiments, fumed silica and its modified forms aid in the thixotropy of the pre-cured or curable composition and provide anti-settling properties during storage. In one or more embodiments, fumed silica and its modified forms also increase the hydrophobicity of the cured coating. In one or more embodiments, fumed silica and its modified forms also increase the anti-abrasion properties of the cured coating. In one or more embodiments, aluminum phyllosilicate clay, organically modified derivatives of aluminum phyllosilicate clay, organically modified bentonite clay, or organically modified montmorillonite clay provide an antistatic based 3D structure thickening effect when included in the pre-cured composition. In one or more embodiments, the aluminum phyllosilicate clay, organically modified derivatives of aluminum phyllosilicate clay, organically modified bentonite clay, or organically modified montmorillonite clay aids in the thixotropy of the pre-settlement or settible composition and provides anti-settling properties during storage.
[0132] In one or more embodiments, the inclusion of an anti-sag rheology modifier in the composition at least reduces sagging or dripping of the curable coating after application onto a substrate, e.g., prevents the coating composition from sagging off a substrate, such as a vertical substrate, when sprayed. In one or more embodiments, the inclusion of an anti-sag rheology modifier in the composition allows for a high build of the curable composition. In one or more embodiments, the properties of the anti-sag rheology modifier can be utilized or activated via high shear and / or high temperature conditions. In one or more embodiments, the anti-sag rheology modifier comprises a wax, a micronized wax, or a combination thereof. In one or more embodiments, the anti-sag rheology modifier comprises a polyamide wax, a micronized polyamide wax, a micronized organically modified polyamide wax, a micronized organically modified polyamide wax derivative, or a combination thereof, or the like. In one or more embodiments, the anti-sag rheology modifier comprises a wax, a derivatized wax, or a combination thereof. In one or more embodiments, the anti-sag rheology modifier comprises a castor oil wax, an organically modified castor oil derivative wax, or a combination thereof. In one or more embodiments, the anti-sag rheology modifier is present in the pre-cured composition in a range of about 0.1 wt % to about 1.5 wt %, or about 0.1 wt % to about 1 wt %, or about 0.1 wt % to about 0.5 wt %, or any weight % or weight range of about 0.1 wt % to about 1.5 wt %, based on the weight % or total weight % of Part A.
[0133] In one or more embodiments, when included in the pre-cured composition, the polyamide wax, micronized polyamide wax, micronized organically modified polyamide wax, micronized organically modified polyamide wax derivative, or combinations thereof, enable high build of the curable composition. In one or more embodiments, when included in the pre-cured composition, the castor oil wax, organically modified castor oil derivative wax, or combinations thereof, provide anti-caking or anti-settling properties during storage of the pre-cured composition, and anti-sagging properties to the curable composition during application to a substrate.
[0134] In one or more embodiments, the inclusion of a surface leveling rheology modifier in the pre-cured composition at least provides smoother leveling of the curable coating when applied and reduces the formation of craters or cavities in the curable coating. In one or more embodiments, the surface leveling rheology modifier comprises a polyether siloxane copolymer. In one or more embodiments, when included in the pre-cured composition, the polyether siloxane copolymer aids in surface leveling due to its wetting properties. In one or more embodiments, the surface leveling rheology modifier is present in the pre-cured composition in a range of about 0.1 wt % to about 1.5 wt %, or about 0.1 wt % to about 1 wt %, or about 0.1 wt % to about 0.5 wt %, or any weight % or weight % range of about 0.1 wt % to about 1.5 wt %, based on the weight % or total weight % of Part A.
[0135] In one or more embodiments of the present disclosure, the rheology modifier comprises, consists essentially of, or consists of aluminum phyllosilicate clay; organically modified derivatives of aluminum phyllosilicate clay; organically modified bentonite clay; organically modified montmorillonite clay, such as Claytone-HY® or Claytone-APA®; organically modified castor oil, such as Thixatrol ST®; micronized organically modified derivatives of polyamide wax, such as Crayvallac Super®; fumed silica; fumed silica surface-modified with dimethyldichlorosilane, such as Cab-O-Sil 610®; micronized barium sulfate, such as VB Techno®; microcrystalline magnesium silicate, such as Talc Silverline 202® or Mistron 002®; polyether siloxane copolymer, such as TEGO® Glide 410® (Evonik); or combinations thereof. In one or more embodiments, the rheology modifier is present in the pre-cured composition in any weight percent range from about 0.3 wt % to about 5 wt %, or from about 0.3 wt % to about 3 wt %, or from about 0.3 wt % to about 1.5 wt %, or from about 0.3 wt % to about 5 wt % to affect the rheological properties of the pre-cured or curable composition.
[0136] Diluent
[0137] As discussed above, one or more embodiments of the present disclosure provide a pre-cured composition that includes a solvent-based monomer (aka solvent-based epoxy resin) and a diluent. In one or more embodiments, the inclusion of a diluent in the pre-cured composition helps reduce the viscosity of the composition, thereby improving processability. In one or more embodiments, the inclusion of a diluent in the pre-cured composition helps reduce the viscosity of the composition, thereby improving processability, provided that a ceramic performance additive, such as hollow ceramic spheres, can be used to thicken the composition beyond a working viscosity (e.g., 3500 cps or less) that may affect the application of the curable composition.
[0138] In one or more embodiments, a diluent can be added to the composition to act as a liquid vehicle to provide a composition viscosity of less than 3500 cps. In one or more embodiments, the diluent has a lower viscosity than the solvent-based monomer, e.g., less than 1000 cps, e.g., from about 1 cps to about 800 cps. In one or more embodiments, the diluent has a viscosity that, when added to the pre-cured composition, results in a final viscosity of the pre-cured composition in the range of about 200 to about 3500 cps, or about 300 to about 3500 cps, thereby maintaining the processability of the pre-cured composition even with the use of ceramic performance additives such as hollow ceramic spheres. In some embodiments, maintaining processability includes maintaining applicability to a substrate by brushing or spray coating.
[0139] In one or more embodiments, the amount of diluent selected for use in the pre-cured composition depends, in part, on the viscosity of the solvent-based monomer / epoxy resin. For example, if the solvent-based monomer has a relatively high viscosity, such as an epoxy-functional monomer having a viscosity of about 10,000 cps to about 20,000 cps, a greater amount of diluent can be added to maintain a working viscosity of about 3500 cps or less of the pre-cured composition. In one or more embodiments, the amount of diluent depends, in part, on whether it is desirable for the composition to have a high solids content (e.g., about 80% to about 90% solids by weight). In such embodiments, it may be desirable to add a smaller amount of diluent, perhaps in combination with a lower viscosity solvent-based monomer. In one or more embodiments, the amount of diluent selected for use in the pre-cured composition depends, in part, on the processability requirements of the pre-cured composition and / or the type of surface or substrate on which the coating is to be formed.
[0140] In one or more embodiments, the diluent is present in the pre-cured composition in a range of about 1% to about 35% by weight, or any weight percent, alternatively, between about 1% to about 35% by weight. In other embodiments, the diluent comprises about 1% to about 15% by weight of the pre-cured composition. In other embodiments, the diluent comprises about 1% to about 20% by weight of the pre-cured composition.
[0141] In some embodiments, the diluent comprises, consists essentially of, or consists of reactive diluents, non-reactive diluents, or combinations thereof that are reactive in the polymerization of the solvent-based monomer / epoxy resin. The type of diluent or combination of diluents selected for use in the pre-cured composition depends, in part, on the performance requirements of the cured coating and / or the type of surface or substrate on which the coating is formed. In some embodiments, a reactive diluent can be selected when it is desired to maintain or increase the mechanical strength (e.g., hardness and / or toughness) of the cured coating, for example, because the diluent becomes incorporated into the polymerization. In other embodiments, a reactive diluent can be selected when it is desired to use a non-volatile diluent, since the diluent is not a volatile organic compound (VOC). In some embodiments, a non-reactive diluent can be selected to reduce costs, since it is generally less expensive than a reactive diluent. In other embodiments, selecting a non-reactive diluent can reduce or prevent air bubbles from being trapped in the cured coating, thereby reducing the porosity of the cured coating. In one or more embodiments, the reactive diluent contributes to the solids content of the cured coating, whereas the non-reactive diluent does not.
[0142] In one or more embodiments, the diluent comprises about 10% by weight of volatile organic compounds, or 10% by weight or less of volatile organic compounds. Volatile organic compounds (VOCs) are compounds with high vapor pressure that can be involved in the photochemical formation of ozone in the presence of heat (e.g., as ground-level smog). Examples of VOC sources include organic solvents, industrial coating operations, paints, household chemicals, and the like. Some VOCs are understood to have low photochemical reactivity and limited impact on ozone generation from changes in emissions. Such VOCs may be excluded from the definition of VOCs for certain regulatory purposes, and are therefore considered "VOC-exempt" as listed by the U.S. Environmental Protection Agency. Thus, in one or more embodiments, a combination of reactive and non-reactive diluents may be selected for a pre-cured composition that includes a lower amount of VOC components, where a lower amount of non-reactive diluent and a higher amount of reactive diluent are used. In some embodiments, selecting such a combination of reactive and non-reactive diluents may reduce the environmental impact of the cured coating and / or reduce the risk of off-gas explosions.
[0143] A reactive diluent of the present disclosure is a diluent that is reactive in the solvent-based monomer / epoxy resin polymerization, for example, in an epoxide polymerization, and thus becomes incorporated into at least the solvent-based monomer polymerization when the pre-cured composition is cured to form a cured coating. In some embodiments, the reactive diluent is reactive in the polymerization of the solvent-based monomer because it contains a functionality that can at least react with the solvent-based monomer, such as, for example, an epoxide functionality (sometimes referred to as a glycidyl ether group), an acrylate functionality, a maleimide functionality, a hydroxyalkyl functionality, or a hydroxide functionality (also known as a hydroxyl functionality).
[0144] In one or more embodiments, the reactive diluent includes poly[(phenyl glycidyl ether)-co-formaldehyde], alkyl (C12-C14) glycidyl ether (e.g., EPODIL 748®), phenyl glycidyl ether, alkenyl substituted phenyl glycidyl ether (e.g., Ultra Lite 513®), butyl glycidyl ether (e.g., Epodil 741®), 2-ethylhexyl glycidyl ether, o-cresol glycidyl ether, cycloaliphatic glycidyl ether, 1,2-epoxy-3-phenoxypropane, epoxy functional polydimethylsiloxane (e.g., Tegomer E-SI 2330®, BYK Silclean 3701®), silicone-amine (e.g., Silamine D2 EDA, Silamine D208 EDA), or combinations thereof. In some embodiments, the reactive diluent comprises butyl glycidyl ether, alkyl (C12-C14) glycidyl ether, or a combination thereof.
[0145] In one or more embodiments, the reactive diluent comprises butyl glycidyl ether, C12-C14 aliphatic glycidyl ether, phenyl glycidyl ether, alkenyl substituted phenyl glycidyl ether, 2-ethylhexyl glycidyl ether, o-cresol glycidyl ether, cycloaliphatic glycidyl ether, 1,2-epoxy-3-phenoxypropane, epoxy functional polydimethylsiloxane, or a combination thereof. In one or more embodiments, the reactive diluent comprises butyl glycidyl ether, C12-C14 aliphatic glycidyl ether, or a combination thereof. In one or more embodiments, the reactive diluent is present in the pre-cured composition in a range of about 1 wt % to about 15 wt %, or about 1 wt % to about 10 wt %, or about 5 wt % to about 10 wt %, or about 1 wt % to about 5 wt %, based on the weight % of part A, or in a range of about 1 wt % to about 10 wt %, or about 2 wt % to about 8 wt %, based on the total weight %, or any weight % range of about 1 wt % to about 15 wt %, based on the weight % of part A or the total weight %.
[0146] In contrast to reactive diluents, the non-reactive diluents of the present disclosure are not reactive in the polymerization of the solvent-based monomer / epoxy resin, and therefore the diluent does not contain reactive functional groups. In one or more embodiments, the non-reactive diluent is an organic solvent. In some embodiments, the non-reactive diluent (e.g., benzyl alcohol) catalyzes the polymerization of the pre-cured composition as it is cured to form a cured coating (e.g., via reactive functional groups such as hydroxyl functional groups (OH)). In some embodiments, the non-reactive diluent evaporates from the curable composition and / or the cured coating, which may be known or referred to as off-gassing. In other embodiments, the non-reactive diluent may be trapped during the polymerization. For example, the non-reactive diluent may be retained in the microstructure of the cured coating. In some embodiments, this may be less desirable, and depending on the amount of diluent retained, retention of the diluent may adversely affect the coating (e.g., by acting as a soft phase in the coating, reducing its hardness) and abrasion resistance. In some embodiments, more than 30 wt. % of the non-reactive diluent may be retained before adversely affecting the coating. Generally, however, for every 5% by weight addition of diluent, the hardness of the cured coating can be expected to decrease by one 3D Shore hardness point.
[0147] In some embodiments, the non-reactive diluent comprises xylene, cyclohexane, toluene, methyl acetate, tert-butyl acetate, nonylphenol, cyclohexane dimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, ethylene glycol (e.g., LIPOXOL 200, LIPOXOL 400 LIPOXOL 600), propylene glycol, phenol, methyl styrenated phenol (e.g., KUMANOX-3114®), styrenated phenol (e.g., KUMANOX-3111F®), C12-C37 ether (e.g., NACOL ETHER 6®, NACOL ETHER 8®), low viscosity hydrocarbon resin (e.g., EPODIL LV5®), aryl polyoxyethylene ether (e.g., Pycal 94®), or a combination thereof. In some embodiments, the non-reactive diluent comprises benzyl alcohol, xylene, methyl acetate, or a combination thereof.
[0148] In some embodiments, the non-reactive diluent comprises xylene, cyclohexane, toluene, methyl acetate, methyl ethyl ketone, tert-butyl acetate, nonylphenol, cyclohexanedimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol, propylene glycol, phenol, or a combination thereof. In some embodiments, the non-reactive diluent comprises benzyl alcohol, xylene, methyl ethyl ketone, methyl acetate, ethers, aromatic solvents, or a combination thereof. In one or more embodiments, the non-reactive diluent is present in the pre-cured composition in a range of about 1 wt % to about 20 wt %, or about 1 wt % to about 10 wt %, or about 5 wt % to about 20 wt %, or about 5 wt % to about 15 wt %, based on the weight % of part A, or in a range of about 1 wt % to about 25 wt %, or about 5 wt % to about 20 wt %, or about 5 wt % to about 15 wt %, based on the total weight %, or any weight % or a weight % range between about 1 wt % to about 25 wt %, based on the weight % of part A or the total weight %.
[0149] In one or more embodiments, the non-reactive diluent is a non-VOC (non-volatile organic compound), such as benzyl alcohol, and can reduce off-gassing from the cured coating. In one or more embodiments, the non-reactive diluent can be selected based on whether it is VOC exempt in the jurisdiction, such as methyl acetate. In some embodiments, the use of a non-VOC or VOC exempt diluent can reduce the environmental impact of the pre-cured composition and / or the cured coating.
[0150] Anti-wear Agent
[0151] One or more embodiments of the present disclosure provide a pre-cured composition further comprising an anti-wear agent. The inclusion of the anti-wear agent in the pre-cured composition improves the corrosion resistance or increases the mechanical strength of the cured coating (compared to a control). In one or more embodiments, the anti-wear agent, in combination with ceramic performance additives such as hollow ceramic spheres and non-hollow ceramics, provides the improved corrosion resistance or increased mechanical strength.
[0152] In one or more embodiments, the antiwear agent comprises, consists essentially of, or consists of graphene nanoplatelets (also called multi-layer graphene flakes), graphite flakes, graphite oxide, graphene, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or combinations thereof. In some embodiments, the antiwear agent comprises, consists essentially of, or consists of graphite oxide, multi-layer graphene flakes (also called graphene nanoplatelets), titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or combinations thereof.
[0153] The type and amount of antiwear agent selected for use in the pre-cured composition will depend, in part, on the performance requirements of the resulting cured coating and / or the type of surface or substrate upon which the coating is formed.
[0154] In some embodiments, the selection of one or a combination of graphene nanoplatelets, graphite flakes, graphite oxide, graphene, titanium dioxide, microcrystalline magnesium silicate, and finely divided barium sulfate as the wear inhibitor can increase corrosion resistance because the additive can act as a high barrier filler. The high barrier filler can increase the diffusion path of water, oxygen, and / or corrosive ions in the coating, making it more difficult for them to reach the surface of the substrate and cause corrosion, thereby increasing the corrosion resistance of the resulting cured coating (compared to a control cured coating). In one or more embodiments, the selection of one or a combination of graphite oxide, graphene, multi-layer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, finely divided barium sulfate, or a combination thereof as the wear inhibitor can increase cavitation resistance, at least in part due to its corrosion resistance. The reduced corrosion of the coated substrate can reduce the occurrence or number of pits or other nucleation sites that could otherwise cause cavitation.
[0155] In some embodiments, one or a combination of graphene nanoplatelets, graphite flakes, graphite oxide can be selected as the anti-wear agent. Graphene nanoplatelets (GNPs) are a subform of graphene, and instead of being one atom thick, GNPs can be thicker and can comprise up to 60 layers of graphene (up to about 30 nm thick). Graphene nanoplatelets may be included because they can exhibit strengths about 300 times greater than steel, hardness greater than diamond, and excellent thermal and electrical conductivity, while being very flexible. Additionally, graphene nanoplatelets can provide solid lubrication, reduce the coefficient of friction of the coating, and / or enhance the foul release effect of the coating. In some embodiments, the selection of graphene nanoplatelets as the anti-wear agent can improve the mechanical and / or bending strength of the resulting cured coating (compared to a control). Additionally, graphene nanoplatelets can be produced in different flake sizes (e.g., 1-100 μm), e.g., large and thin flakes with high surface area. These large, thin flakes, when incorporated into a coating, can act as a physical and / or chemical barrier against corrosion. Due to their large surface area, lower concentrations of graphene nanoplatelets are required to provide a barrier against corrosion. In some embodiments, the selection of graphene nanoplatelets as a wear inhibitor can improve the corrosion resistance of the resulting cured coating (relative to a control).
[0156] In some embodiments, one or a combination of titanium dioxide and microcrystalline magnesium silicate may be selected as the anti-wear agent to enhance corrosion resistance by acting as a high barrier filler (compared to a control). In some embodiments, the mechanical strength of the resulting cured coating may be improved (compared to a control) by selecting titanium dioxide, microcrystalline magnesium silicate, fumed silica, or a combination thereof as the anti-wear agent.
[0157] As mentioned above, one or a combination of fumed silica and titanium dioxide may also be selected to further act as a ceramic performance additive. In some embodiments, one or a combination of fumed silica, microcrystalline magnesium silicate, and finely divided barium sulfate may be selected to further act as a rheology modifier. In some embodiments, finely divided barium sulfate may be selected to further act as a sound deadening additive and may act in conjunction with the hollow ceramic spheres to reduce the noise emission of the cured coating.
[0158] In one or more embodiments, the anti-wear agent is present in the pre-cured composition in a range of about 0.5 wt% to about 5 wt%, or about 0.5 wt% to about 2 wt%, or any weight percent, or any weight percent range between 0.5 wt% and about 5 wt%. In one or more embodiments, the anti-wear agent is present in the pre-cured composition in a range of about 0.01 wt% to about 1 wt%, or about 0.05 wt% to about 0.5 wt%, or about 0.05 wt% to about 0.8 wt%, or any weight percent range between 0.01 wt% to about 1 wt%, based on the total weight percent.
[0159] Hydrophobicity Control Additive
[0160] In one or more embodiments of the present disclosure, the pre-cured composition further comprises a hydrophobicity adjusting additive. The inclusion of a hydrophobicity adjusting additive in the pre-cured composition can increase the hydrophobicity of the cured coating. Increasing the hydrophobicity of the cured coating can improve the antifouling / fouling release properties of the coating (compared to a control epoxy-based coating). In addition to the hydrophobicity adjusting additive, one or more of the hybrid epoxy siloxane resins and silane adhesion promoters described herein can also increase the hydrophobicity of the resulting cured coating.
[0161] Generally, fouling occurs because organisms compete with water for binding to a surface. Therefore, it is desirable for a surface to have favorable properties for the attachment of organisms. For some organisms (e.g., micro-foulers), there is a zone of minimal biofouling at a surface tension of about 22-24 mN / m. The most unfavorable surface energy for biofouling is about 23 mN m -1 The range is about 20 to about 25 mN m -1 , or about 20 to 30 mN m -1 In this case, biofouling is minimal due to the formation of a weak boundary layer between the surface and the adhesive protein of the fouling organism. For example, surfaces containing methyl silicone generally have surface energies in this range. Another factor in whether fouling occurs is surface roughness, and a smoother surface (e.g., a surface without defects) provides less space and surface area for fouling organisms to attach.
[0162] Generally, about 20 to about 25 mNm -1 Surfaces with energies approaching the range of 0.1 to 0.5 mN m can reduce the surface adhesion of fouling organisms. This is because at this surface energy, the thermodynamic cost of water rewetting the surface is minimized, while surface movement removes weakly bound foulants due to the shear stress acting on the coating. Hydrophobicity-modifying additives contribute to lowering the surface energy of the coating by increasing the hydrophobicity of the cured epoxy-based coating (e.g., about 20 to about 25 mN m). -1to the range of 0.1 to 1.0 nm), which can reduce the adhesion of fouling organisms to the cured coating, thereby improving antifouling / fouling release properties. The hydrophobicity controlling additives of the present disclosure, as well as the hybrid epoxy siloxane resins and silane adhesion promoters described herein, can increase the hydrophobicity of the cured epoxy-based coating due to the hydrophobic properties of the components themselves. In some embodiments, the hydrophobicity controlling additive's hydrophobicity properties are due in part to the additives including alkyl- or aryl-based functional groups. For example, the hydrophobicity controlling additives can include alkyl- or aryl-based functional groups including carbon chain lengths of 1-15, or carbon ring sizes of 1-10. In some embodiments, the hydrophobicity controlling additive's hydrophobicity properties are due in part to the additives having higher molecular weights (e.g., polymeric additives vs. small molecule additives). Without wishing to be bound by theory, one or more of the hydrophobicity adjusting additives, hybrid epoxy siloxane resins, and silane adhesion promoters described herein may increase the hydrophobicity of the cured coating due, at least in part, to portions of the additive (e.g., portions that are not reactive in epoxide polymerization) that migrate to the surface of the coating as it cures.
[0163] In one or more embodiments, the hydrophobicity-controlling additive is reactive in an epoxide polymerization and thus becomes incorporated into the polymerization of at least the epoxy-functional monomer as the pre-cured composition cures. In some embodiments, the hydrophobicity-controlling additive is reactive in an epoxide polymerization because it contains a functional group capable of reacting with at least the epoxy-functional monomer, such as an epoxy functional group. In other embodiments, the hydrophobicity-controlling additive becomes trapped during said polymerization. In some embodiments, the hydrophobicity-controlling additive comprises an epoxy-functional silane, an epoxy-functional polydialkylsiloxane, or a combination thereof.
[0164] In some embodiments, when the hydrophobicity controlling additive comprises an epoxy-functional silane, an epoxy-functional polydialkylsiloxane, or a combination thereof, the hydrophobicity controlling additive may further function as a reactive diluent due at least in part to their relatively low viscosity (e.g., a viscosity of less than 1000 cps, such as from about 1 cps to about 800 cps).
[0165] In some embodiments, the hydrophobicity adjusting additive is not reactive in the epoxide polymerization, but becomes embedded when the pre-cured composition is cured into a cured epoxy-based coating. In such embodiments, the hydrophobicity adjusting additive may include polydimethylsiloxane (PDMS)-silica or fumed silica, which may be applied (e.g., sprayed, brushed, etc.) to the surface of the coating as it cures into the cured epoxy-based coating to increase the hydrophobicity of the cured coating.
[0166] The type and amount of hydrophobicity controlling additive selected for use in the pre-cured composition will depend, in part, on the performance requirements of the cured coating and / or the type of surface or substrate upon which the coating is formed.
[0167] In some embodiments, the Si-based additives are selected for their hydrophobic properties and are maintained at low concentrations in the pre-cured composition so as not to affect the mechanical strength of the cured coating. In some embodiments, the hydrophobicity adjusting additive comprises or consists essentially of an epoxy-functional polydialkylsiloxane. In some embodiments, the epoxy-functional polydialkylsiloxane comprises or consists essentially of an epoxy-functional polydimethylsiloxane. Epoxy-functional polydimethylsiloxane and similar epoxy-functional polydialkylsiloxanes can be selected when a large reduction in coating surface energy (i.e., a large increase in coating hydrophobicity) is required to increase the antifouling / fouling release properties of the cured coating (compared to the control cured coating). In some embodiments, the epoxy functional polydimethylsiloxane is present in the pre-cured composition in the range of about 0.05% to about 5% by weight, or about 0.5% to about 5% by weight, or about 1% to about 3% by weight, or any weight % or any weight % range from about 0.05% to about 5% by weight, based on the weight % or total weight % of Part A, to affect the antifouling / foul release properties of the cured coating.
[0168] In some embodiments, the hydrophobicity adjusting additive comprises or consists essentially of an epoxy functional silane. In some embodiments, the epoxy functional silane comprises, consists essentially of, or consists of glycidoxypropyltrimethoxysilane. Glycidoxypropyltrimethoxysilane and similar epoxy functional silanes can be selected to enhance the adhesion of the cured coating to the substrate in addition to enhancing the hydrophobicity of the coating. For example, glycidoxypropyltrimethoxysilane can promote adhesion through its trimethoxysilane moiety. Such trimethoxy functional groups are susceptible to hydrolytic degradation and thus form reactive silanol functional groups that can react with other reactive functional groups, such as hydroxyl (OH) groups, on the surface of the substrate, thereby promoting adhesion. In some embodiments, glycidoxypropyltrimethoxysilane is present in the pre-cured composition in the range of about 0.05% to about 5% by weight, or about 0.5% to about 5% by weight, or about 1% to about 3% by weight, or any weight %, or any weight % range from about 0.05% to about 5% by weight, based on the weight % or total weight % of Part A, to affect the antifouling / fouling release properties of the cured coating.
[0169] Dispersants
[0170] One or more embodiments of the present disclosure provide a pre-cured composition that further comprises a dispersant for dispersing solid components in the composition (see, e.g., Example 1, Section 1.1, Example 2, Example 3). In some embodiments, including a dispersant in the pre-cured composition maintains the solid components suspended in the composition. In other embodiments, including a dispersant in the pre-cured composition improves the shelf life of the composition. For example, including a dispersant can maintain all components of the pre-cured composition in suspension, such that none of the components settle or precipitate from the composition.
[0171] In one or more embodiments of the present disclosure, the dispersant is a polymeric dispersant. In some embodiments, the polymeric dispersant comprises a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof. In one or more embodiments, the dispersant is selected from the group consisting of ADDITOL VXW 6208® (polymeric non-ionic dispersant), K-SPERSE A504® (polymeric non-ionic dispersant), Disperbyk 140® (polymeric ionic dispersant, alkyl ammonium salt of an acidic polymer), MULTIWET EF-LQ-AP® (polymeric non-ionic dispersant), HPERMER KD6-LQ-MV® (polymeric non-ionic dispersant blend), ECO NatraSense 125 MBAL-LQ-AP® (non-ionic alcohol ethoxylate dispersant), BRIJ-03-LQ-AP® (non-ionic alkyl polyglycol ether dispersant), SP BRIJ 02 MBAL LQ-AP® (non-ionic alkyl polyglycol ether dispersant), ANTI-TERRA-204® (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670® (polymeric non-ionic dispersant), TEGO Dispers 1010® (polymeric non-ionic dispersant), TEGO® Glide 410® (polyether siloxane copolymer), or combinations thereof.In one or more examples, the dispersant may be ADDITOL VXW 6208® (polymeric nonionic dispersant), K-SPERSE A504 (polymeric nonionic graphene dispersant), MULTIWET EF-LQ-AP® (polymeric nonionic dispersant), HPERMER KD6-LQ-MV® (polymeric nonionic dispersant blend), BRIJ-03-LQ-AP® (nonionic alkyl polyglycol ether dispersant), SP BRIJ 02 MBAL LQ-AP® (nonionic alkyl polyglycol ether dispersant), ANTI-TERRA-204® (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670® (polymeric nonionic dispersant), TEGO Dispers 1010® (polymeric nonionic dispersant), TEGO® Glide® 410® (polyether siloxane copolymer), or combinations thereof.
[0172] The type and amount of dispersant selected for use in the pre-cured composition will depend, in part, on the performance requirements of the cured coating, the type of ceramic performance additive used, the type of antiwear agent used, and / or the desired shelf life of the pre-cured composition.
[0173] In one or more embodiments, the dispersant is selected from the group consisting of ADDITOL VXW 6208® (polymeric non-ionic dispersant), K-SPERSE A504 (polymeric non-ionic dispersant), Disperbyk 140® (polymeric ionic dispersant, alkyl ammonium salt of an acidic polymer), MULTIWET EF-LQ-AP® (polymeric non-ionic dispersant), HPERMER KD6-LQ-MV® (polymeric non-ionic dispersant blend), ECO NatraSense 125 MBAL-LQ-AP® (non-ionic alcohol ethoxylate dispersant), BRIJ-03-LQ-AP® (non-ionic alkyl polyglycol ether dispersant), SP BRIJ 02 MBAL LQ-AP® (non-ionic alkyl polyglycol ether dispersant), ANTI-TERRA-204® (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670® (polymeric non-ionic dispersant), TEGO Dispers 1010® (polymeric non-ionic dispersant), TEGO® Glide 410® (polyether siloxane copolymer), or combinations thereof.
[0174] In some embodiments, the dispersant selected is ADDITOL VXW 6208® (polymeric non-ionic dispersant), TEGO® Glide 410® (polyether siloxane copolymer), or Disperbyk 140® (polymeric ionic dispersant, alkyl ammonium salt of acidic polymer), any of which can provide a wetting and / or stabilizing effect. In one or more embodiments, TEGO® Glide 410® (polyether siloxane copolymer) can also act as a rheology modifier. In some embodiments, the dispersant selected is K-SPERSE A504 (polymeric non-ionic dispersant), which can provide efficient dispersion of pigments, such as submicron pigments, or other fine-grade solids, such as titanium dioxide or graphene nanoplatelets. In some embodiments, the dispersant selected is MULTIWET EF-LQ-AP® (polymeric non-ionic dispersant, HPERMER KD6-LQ-MV® (polymeric non-ionic dispersant blend), SP BRIJ 02 MBAL LQ-AP® (non-ionic alkyl polyglycol ether dispersant), or BRIJ-03-LQ-AP® (non-ionic alkyl polyglycol ether dispersant), any one of which can act as a wetting agent and / or provide anti-settling properties depending on the steric properties of the components being suspended. In some embodiments, the dispersant is ECO NatraSense 125 MBAL-LQ-AP® (non-ionic alcohol ethoxylate dispersant), which can provide improved dispersion over low energy surfaces (e.g., surfaces that are difficult to wet) due to the hydrophilic nature of the dispersant.In some embodiments, the dispersant selected is ANTI-TERRA-204® (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670® (polymeric non-ionic dispersant), or TEGO Dispers 1010® (polymeric non-ionic dispersant), any of which can be based on acrylics, polyesters, adducts of polycarboxylic acids with amines, etc., and can provide good dispersion in both aqueous-borne and solvent-borne systems.
[0175] In one or more embodiments, the dispersant is present in the pre-cured composition in a range of about 0.1 wt % to about 5 wt %, or about 0.1 wt % to about 4 wt %, or about 0.1 wt % to about 3 wt %, or about 0.1 wt % to about 2 wt %, or about 0.1 wt % to about 1 wt %, or any weight % or weight % between about 0.1 wt % to about 5 wt %, based on the weight % or total weight % of Part A.
[0176] Defoamer
[0177] One or more embodiments of the present disclosure provide a pre-cured composition that further comprises an antifoaming agent. In some embodiments, the inclusion of an antifoaming agent in the pre-cured composition reduces or inhibits the formation of air entrapment / bubbles in the cured coating. In some embodiments, the inclusion of an antifoaming agent in the pre-cured composition reduces or inhibits bubble formation during processing and application of the composition. Reducing or inhibiting the formation of air entrapment / bubbles in the cured coating also reduces or inhibits the formation of defects (e.g., reducing roughness, reducing porosity, improving coating uniformity) that may otherwise result in erosion or cavitation of the substrate (e.g., when the substrate is a propeller).
[0178] In one or more embodiments, the defoamer comprises a polymeric defoamer. In one or more embodiments, the defoamer comprises a silicone-based oligomeric defoamer. In some embodiments of the present disclosure, the defoamer comprises a silicone-modified defoamer or a silicone-free defoamer. The defoamer acts by penetrating and breaking down the foam lamellae. In some embodiments, the defoamer comprises BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airex 900, or a combination thereof. In some embodiments, the silicone-modified defoamer comprises, consists essentially of, or consists of BYK-066 N. BYK-066 N is a silicone defoamer for use in solventless or solvent-based coatings. In some embodiments, the silicone-free defoamer comprises, consists essentially of, or consists of BYK-1790. BYK-1790 is a silicone-free polymeric defoamer for solvent-free coatings, suitable for pigmented and non-pigmented coating systems. In some embodiments, the silicone modified defoamer comprises, consists essentially of, or consists of ADDITOL VXW 6210 N. ADDITOL VXW 6210 N is a silicone modified defoamer useful as a defoamer or air release defoamer. In some embodiments, the silicone modified defoamer comprises, consists essentially of, or consists of TEGO Airex 900. TEGO Airex 900 is an organo-modified polysiloxane defoamer containing fumed silica and is useful as a concentrated defoamer to address both micro- and macro-bubbles.
[0179] The type and amount of defoamer selected for use in the pre-cured composition will depend, in part, on the performance requirements of the epoxy-based coating and / or the tendency of the cured coating to form bubbles. In one or more embodiments, any one or combination of BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airex 900 can be selected to reduce or inhibit bubble formation in the cured coating and / or during processing and application of the composition.
[0180] In one or more embodiments, the antifoaming agent is present in the pre-cured composition in a range of from about 0.1 wt % to about 5 wt %, or from about 0.1 wt % to about 1.5 wt %, or from about 0.3 wt % to about 1.2 wt %, or from about 0.1 wt % to about 1 wt %, or from about 1 wt % to about 5 wt %, or any weight % or weight range of from about 0.1 wt % to about 5 wt %, based on the weight % or total weight % of Part A.
[0181] Weather Resistant Additives
[0182] One or more embodiments of the present disclosure provide a pre-cured composition further comprising a weathering additive. In some embodiments, the inclusion of a weathering additive in the pre-cured composition provides improved chemical stability to the resulting cured coating, protects the cured coating from UV degradation, or protects the cured coating from thermal degradation. In some embodiments, the inclusion of a weathering additive in the pre-cured composition improves UV and thermal stability, and the additive can prevent or reduce the autocatalytic degradation of the cured coating in which it is incorporated and any resulting mechanical collapse, for example, by quenching free radicals formed by heat or UV irradiation. In some embodiments, the weathering additive can promote or improve adhesion promotion to metal substrates.
[0183] In some embodiments, the weathering additive also acts as an adhesion promoter. In one or more embodiments, when the ceramic performance additive is added to the composition to improve the sound deadening properties of the cured coating, the weathering additive is included in the pre-cured composition as an adhesion promoter, which is then applied to the substrate as an undercoat. In one or more embodiments, when the ceramic performance additive is added to the composition to improve the scratch resistance of the cured coating, the weathering additive is included in the pre-cured composition, which is then applied to the substrate as a topcoat. In one or more embodiments, when the hollow ceramic spheres having a particle size of about 10 μm to about 15 μm are added to the composition to improve the scratch resistance of the cured coating, the weathering additive is included in the pre-cured composition, which is then applied to the substrate as a topcoat.
[0184] In one or more embodiments, the weathering additive comprises a hydroxyphenyl-benzotriazole, a hydroxyphenyl-triazine, or a combination thereof. In one or more embodiments, the weathering additive comprises 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl ester and 5% 1-methoxy-2-propyl acetate (e.g., Tinuvin 99-2®). In one or more embodiments, the weathering additive comprises 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (e.g., Tinuvin 900®). In one or more embodiments, the weathering additive includes 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (e.g., Tinuvin 400®). In one or more embodiments, the weathering additive is present in the pre-cured composition in a range of about 0.5% to about 5% by weight, or about 1% to about 5% by weight, or any weight % or weight % range of about 0.5% to about 5% by weight, based on the weight % of Part A.
[0185] curing catalyst
[0186] One or more embodiments of the present disclosure provide a pre-cured composition further comprising a curing catalyst that is reactive in promoting the curing of the pre-cured composition to form a cured coating.
[0187] In some embodiments, the curing catalyst is reactive in promoting curing so as to catalyze the polymerization and / or crosslinking of the pre-cured composition. In other embodiments, the curing catalyst can act as a crosslinker in the reaction as well as catalyze the polymerization and / or crosslinking of the pre-cured composition. In some embodiments, the curing catalyst can catalyze the polymerization and / or crosslinking of the pre-cured composition at lower reaction temperatures (e.g., from about -5°C to about 0°C). In some embodiments, the curing catalyst is reactive because it contains a functional group, such as an amine functional group, that can react with at least the solvent-based monomer when the pre-cured composition is cured.
[0188] In some embodiments, a curing catalyst is used when the solvent-based monomer used in the pre-cured composition includes an epoxy-functional epoxide siloxane monomer. In some embodiments, the curing catalyst can increase crosslinking of the epoxide component of the epoxy-functional epoxide siloxane monomer.
[0189] In some embodiments, the curing catalyst is included in the pre-cure composition and does not begin to catalyze the polymerization and / or crosslinking of the composition until a curing agent is added to the composition (i.e., see hardener composition below), in other embodiments, the curing catalyst is included in the hardener composition and begins accelerating the cure upon addition to the pre-cure composition.
[0190] In some embodiments, a curing catalyst is used to cure the pre-cured composition (described below) when the selected curing agent reacts slowly at or below ambient temperatures (e.g., when the curing agent is a polyamine). In other embodiments, when the selected curing agent reacts rapidly at or below ambient temperatures (e.g., when the curing agent is a phenalkamine), a curing catalyst may not be necessary.
[0191] In some embodiments, the curing catalyst comprises an alcohol, such as 2,4,6-tris[(dimethylamino)methyl]phenol, which may be included in the pre-curing composition or the curing agent. The use of an alcohol as a curing catalyst simplifies the adjustment of the cure rate, thereby eliminating the need to recalculate the curing agent to match the stoichiometry of the epoxy. The alcohol curing catalyst can be added until the desired reactivity is achieved or until some performance property of the cured coating drops to an unacceptable level, requiring further reformulation.
[0192] In some embodiments, a curing catalyst is included in the pre-cure composition or in the curing agent if the curable composition is not completely cured, if the coating needs to be cured at a lower temperature, and / or if the coating takes too long to cure (e.g., a week to cure).
[0193] In some embodiments, 2,4,6-tris[(dimethylamino)methyl]phenol can be selected as a curing catalyst. In some embodiments, 2,4,6-tris[(dimethylamino)methyl]phenol can be added to the curing agent to catalyze the curing of the pre-cured composition. In other embodiments, 2,4,6-tris[(dimethylamino)methyl]phenol can be selected to catalyze the curing of the pre-cured composition at lower temperatures. In some embodiments, 2,4,6-tris[(dimethylamino)methyl]phenol is present in the curing agent in a range of about 1% to about 5% by weight, or any weight percent range of about 1% to about 5% by weight, to affect the catalysis of the curing of the pre-cured composition.
[0194] In some embodiments, the wet / dry adhesion promoter may also act as a curing catalyst. In some embodiments, when the wet / dry adhesion promoter comprises a polymer or prepolymer containing mercaptans, or a combination thereof (also referred to herein as CAPCURE® 3-800 or CAPCURE® 40 SEC HV (Huntsman)), the wet / dry adhesion promoter may also act as a curing catalyst. In some embodiments, the weathering additive (which may also act as a wet / dry adhesion promoter) comprises 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (also referred to as Tinuvin 99-2® or Tinuvin 900®), the weathering additive may also act as a curing catalyst.
[0195] Hardener Composition
[0196] In one or more embodiments of the present disclosure, one or more pre-cured compositions can be used to form a cured coating by reacting the composition with a curing agent composition, which includes a curing agent and optionally a diluent.
[0197] In one or more embodiments, the curing agent is reactive upon curing of the composition to form a coating that is resistant to at least 50 passes of an organic solvent abrasion when measured according to ASTM D1640. In one or more embodiments, the curing agent is reactive upon curing of the composition to form a coating that is resistant to about 50-80 passes of an organic solvent abrasion when measured according to ASTM D1640. In some embodiments, the curing agent is reactive upon curing of the composition to form a coating that is resistant to at least 50 passes of an organic solvent abrasion when cured at room or ambient temperature. In some embodiments, the curing agent is reactive upon curing of the composition to form a coating that is resistant to at least 50 passes of an organic solvent abrasion when cured at room or ambient temperature 20 hours after application.
[0198] In one or more embodiments, the curing agent is present in the curing agent composition in a range of about 70% to about 100% by weight. In one or more embodiments, when the curing agent composition includes a diluent, the diluent includes a non-reactive diluent such as methyl acetate, xylene, or a combination thereof. In one or more embodiments, when the curing agent composition includes a diluent, the diluent includes xylene, benzyl alcohol, methyl ethyl ketone, methyl acetate, an ether, an aromatic solvent, or a combination thereof. In one or more embodiments, when the curing agent composition is stored prior to use, the diluent includes xylene, benzyl alcohol, an ether, an aromatic solvent, or a combination thereof. In some embodiments, the use of the diluent methyl ethyl ketone, methyl acetate, or a combination thereof may decrease the shelf life or storage stability of the curing agent composition.
[0199] In one or more embodiments, the diluent is present in the hardener composition in any weight percent or weight percent range of about 1-30% by weight, or about 1-25% by weight, or about 5-25% by weight, or about 10-25% by weight, or about 1-5% by weight, or about 1-30% by weight. In one or more embodiments, the diluent is present in the hardener composition in any weight percent or weight percent range of about 1-30% by weight, or about 1-20% by weight, or about 1-30% by weight. In some embodiments, the diluent is present in the hardener composition in any weight percent or weight percent range of about 1-30% by weight. In some embodiments, the diluent includes xylene present in a range of about 1% by weight to about 5% by weight, and includes methyl acetate present in a range of about 10% by weight to about 25% by weight.
[0200] The curing agents of the present disclosure can induce, and in some cases participate in, a curing reaction (e.g., polymerization and / or crosslinking of at least the solvent-based monomers) that converts the pre-cured composition into an infusible, insoluble polymer network that is the cured coating. In some embodiments, the curing agent participates in the curing reaction by acting as a crosslinker. Generally, curing involves crosslinking and / or chain extension through the formation of covalent bonds between individual chains of a polymer (e.g., formed by polymerizing at least the solvent-based monomers), thereby forming a rigid three-dimensional structure and high molecular weight (e.g., a cured coating).
[0201] In one or more embodiments, polymerization and / or crosslinking induced and / or involved by the curing agent results in a crosslinked, cured coating of higher molecular weight, which contributes to the coating's hardness and / or resistance to abrasive treatments with organic solvents.
[0202] The curing agents of the present disclosure are reactive in the polymerization of solvent-based monomers, such as epoxide polymerization, and may be incorporated (e.g., as crosslinkers) in the polymerization of at least the solvent-based monomers when the pre-cured composition is cured to form a cured coating. In some embodiments, the curing agent is reactive in the polymerization because it includes a functional group that can at least react with the solvent-based monomers (also referred to herein as solvent-based epoxy resins), such as an amine functional group, or an amide functional group, or a silane functional group.
[0203] The hardener of the present disclosure begins to induce the curing reaction upon addition to the pre-cured composition. Thus, the pre-cured composition and the hardener can be provided in two separate containers, one containing the composition and the other containing the hardener. In some embodiments, these are referred to as two-component (or "two-component" or "two-part") resin systems. To use such systems, the pre-cured composition is first mixed with the hardener, which induces the composition to cure to form an infusible, insoluble polymer network. The resulting mixture is then applied to a substrate. Generally, no application of heat or radiation is required to cure a two-component resin system. In some embodiments, the two-component resin system can cure in as little as two minutes or require longer times, depending on the nature and concentration of the resin / catalyst / hardener and the curing conditions (e.g., lower temperature).
[0204] In some embodiments of the present disclosure, the curing agent comprises an amine curing agent, an amide curing agent, or a combination thereof. In some embodiments, the curing agent is a polymer. In one or more embodiments, the curing agent is a resin reactive in epoxy polymerization. In such embodiments, the curing agent contributes to the total weight percent of the resin in the curable composition. In other embodiments, the curing agent is a small molecule. For example, in some embodiments, the amine curing agent, the amide curing agent, or a combination thereof comprises a phenalkamine, an amine-modified phenalkamine, a phenalkamide, an amine-modified phenalkamide, a polyamidoamine, an organically modified polyamidoamine, or a combination thereof. In some embodiments, the amine hardener, amide hardener, or combination thereof is selected from the group consisting of phenalkamine, West System® Hardener Extra Slow 209, West System® 206 Slow Hardener, WEST SYSTEM® 205 Slow Hardener, West System Hardener Fast 205, PRIAMINE 1071-LQ-GD (polyamine), GX-1120XB80(KH) (polyamide), KMH-100 (phenalkamine), DNST, KH 3001-Accelerator (triamine), EPIKURE 3292FX60, EPIKURE 3253, and GX-1120XB80(KH) (polyamide), Cardolite NX-5444 (phenalkamine), DOCURE KMH-100 (phenalkamine hardener, kukdo chemecal), Ancamide 2832 (Evonik, a modified polyamidoamine), ANCAMIDE® 2137 (Evonik, a modified polyamidoamine), Ancamine 2811 (Evonik, an amine modified phenalkamine), Dynasylan TRIAMO (Evonik), Ancamide 3201 (Evonik).
[0205] In one or more embodiments, the curing agent can be selected to form a coating that is resistant to organic solvent abrasion of at least 50 passes when cured at room temperature as measured according to ASTM D1640. In one or more embodiments, the curing agent can be selected to form a coating that is resistant to organic solvent abrasion of 50 to 80 passes when measured according to ASTM D1640. The curing agent selected to form a coating that is resistant to organic solvent abrasion can provide a fast cure and, in embodiments where the cured coating is applied as an undercoat, can facilitate improved intercoat or recoat adhesion with any applied topcoat, in combination with an adhesion promoter. In some embodiments, such curing agents include Cardolite NX-5444 (phenalkamine), DOCURE KMH-100 (phenalkamine curing agent, kukdo chemecal), Ancamide 2832 (Evonik, ANCAMIDE® 2137 (Evonik, modified polyamidoamine), Ancamine 2811 (Evonik, amine modified phenalkamine), or Andisil 1100, Dynasylan AMEO (aminopropyltriethoxysilane).
[0206] In some embodiments, a particular hardener (i) allows for a longer time for applying the mixture of pre-cured composition and hardener to a substrate (e.g., long working time) and the cured coating has a good surface finish (gloss) (A West System Hardener Extra Slow 209); (ii) has a low temperature cure, fast recoat window, and short working time (West System Hardener Fast 205); (iii) the cured coating has good water resistance, long pot life, increased hydrophobicity, and good surface finish (gloss) and the coating cures at ambient temperature (PRIAMINE 1071-LQ-GD, polyamine), (iv) cured coatings with very good surface appearance, few surface defects, long cure times (GX-1120XB80(KH), polyamide), (v) cured coatings that are hard and hydrophobic, use of natural sources (green chemistry) for the curing agent, and have low temperature cure (KMH-100, phenalkamine), and / or (vi) in combination with, for example, polyamides / polyamines to catalyze the cure reaction (KH 3001 -Accelerator, triamine, EPIKURE 3253), (vii) lower viscosity and reduced or suppressed bubbles due to VOC content (EPIKURE 3292FX60, 60% xylene / butanol, GX-1120XB80(KH), polyamide).
[0207] In one or more embodiments, when the epoxy functional monomer of the pre-cured composition includes an epoxy functional epoxide siloxane monomer (also referred to herein as a hybrid epoxy siloxane resin), a specific curing agent can be selected. When the epoxy functional monomer is an epoxy functional epoxide siloxane monomer, the curing agent selected can include a silamine curing agent (also referred to as an aminosilane curing agent). The silamine curing agent includes a silane functional group (e.g., SH) and an amine functional group (e.g., a primary amine group and a secondary amine group). Without wishing to be bound by theory, the silane functional group can crosslink with the siloxane side chain of the epoxy functional epoxide siloxane monomer during curing, and / or the amine functional group can crosslink with the epoxy functional group of the epoxy functional epoxide siloxane monomer during curing.
[0208] In one or more embodiments, the silamine curing agent can be selected from aminopropyltriethoxysilane (Andisil 1100, or Dynasylan® AMEO), bis(3-triethoxysilylpropyl)amine (Dynasylan 1146), or N-2-aminoethyl-3-aminopropyltrimethoxysilane (Dynasylan DAMO), or combinations thereof. In one or more embodiments, the silamine curing agent can be selected from aminopropyltriethoxysilane (Andisil 1100, or Dynasylan® AMEO), bis(3-triethoxysilylpropyl)amine (Dynasylan 1146), or N-2-aminoethyl-3-aminopropyltrimethoxysilane (Dynasylan DAMO), triaminofunctional propyltrimethoxysilane (Dynasylan TRIAMO (Evonik)), or combinations thereof. In one or more embodiments, the amount of silamine curing agent used to cure the pre-cured composition is calculated based on the amine equivalent weight of the curing agent, with the epoxy to amine ratio maintained at equimolar (e.g., see below).
[0209] In one or more embodiments, when the curing agent comprises an amine curing agent such as a phenalkamine, the stoichiometric ratio of monomer (e.g., epoxy functional monomer) to curing agent is non-equimolar stoichiometric ratio, or about 1.2 to 1.6, or about 1.4 to 1.6. In one or more embodiments, when the curing agent comprises an amine curing agent, the stoichiometric epoxy group / NH ratio is about 1.2 to about 1.4, or about 1.2. In one or more embodiments, when the curing agent comprises a polyamidoamine, the stoichiometric ratio of monomer (e.g., epoxy functional monomer) to curing agent is equimolar stoichiometric (ratio 1.0). In one or more embodiments, when the curing agent comprises an aminopropyltriethoxysilane or a triaminofunctionalpropyltrimethoxysilane, the stoichiometric ratio of monomer (e.g., epoxy functional monomer) to curing agent is equimolar stoichiometric (ratio 1.0). In one or more embodiments, when the curing agent comprises aminopropyltriethoxysilane or triaminofunctional propyltrimethoxysilane, the epoxy group / NH ratio is from about 0.9 to about 1.1, or about 1.
[0210] In some embodiments, the curing agent is selected so that the degree of crosslinking that occurs during curing of the pre-cured composition is from about 60% to about 99%, or from about 70% to about 99%, or from about 80% to about 99%, or from about 90% to about 99%, or about 99%.
[0211] In some embodiments, the curing agent is reactive upon curing the pre-cured composition to form a cured coating at temperatures from about -5°C to about 100°C. In some embodiments, the curing agent is reactive upon curing the pre-cured composition to form a cured epoxy-based coating at ambient temperatures and conditions. In other embodiments, the curing agent is selected such that the pre-cured composition can be cured at lower reaction temperatures (e.g., from about -5°C to about 0°C). In some embodiments, the curing agent comprises a phenalkamine.
[0212] In some embodiments, to affect the curing of the pre-cured composition, the curing agent of the present disclosure is added to the composition at a resin to curing agent ratio of 1:1 to 1:1 / 5, or 1:2.3 to 1:3. In some embodiments, by selecting a ratio of 1:2.3 to 1:3, the curing reaction rate can be increased, which can facilitate curing at low temperatures. In some embodiments, the curing agent of the present disclosure is added to the composition at a resin to curing agent ratio of 1:1 to 1:2, or at an epoxy group / NH ratio of about 1.2 to 1.4. When the ratio is 1.1 to 1.2, or 1.2 to 1.4, less curing agent is used, and using less curing agent may improve the recoat window, reduce the curing reaction rate, and / or increase the flexibility of the cured coating. In other embodiments, using too little hardener relative to the resin can lead to an incomplete curing reaction, reducing mechanical properties and / or causing the coating to fail, while using too much hardener relative to the resin can accelerate the curing reaction and leave unreacted hardener on the coating, causing loss or reduction in coating functionality.
[0213] In one or more embodiments of the present disclosure, any one or more of the graphene nanoplatelets, adhesion promoters, dispersants, antifoam agents, rheology modifiers, cure catalysts (not including additives reactive in the polymerization of solvent-based monomers), other anti-wear agents, hollow ceramic spheres, or other ceramic performance additives may be first added and / or dispersed in the curing agent before being added to any one or more of the pre-cured compositions of the present disclosure.
[0214] Method and substrate application
[0215] As noted above, one or more embodiments of the present disclosure provide a method for forming one or more pre-cured compositions.
[0216] In one or more embodiments of the present disclosure, the method includes mixing together a solvent-based resin, a diluent, an adhesion promoter, a rheology modifier, and a ceramic performance additive, and forming a coating composition. In one or more embodiments, the method further includes mixing a dispersant, an antifoam agent, and / or an antiwear agent.
[0217] In one or more embodiments of the present disclosure, the method includes mixing the solvent-based monomer, diluent, adhesion promoter, and hollow ceramic spheres together and forming a coating composition. In some embodiments, the method further includes mixing a rheology modifier, a dispersant, an antifoaming agent, and / or an antiwear agent. In some embodiments, when an antiwear agent is mixed, mixing the solvent-based monomer, diluent, adhesion promoter, and hollow ceramic spheres together includes mixing the solvent-based monomer, diluent, and adhesion promoter together, grinding the antiwear agent, mixing the ground antiwear agent into the mixture of the solvent-based monomer, diluent, and adhesion promoter, and mixing into the hollow ceramic spheres.
[0218] In one or more embodiments, a method for forming one or more pre-cured compositions includes the following (see Example 1 for further details). The main components of the pre-cured coating include A) resin paste, B) anti-wear agent base, C) let-down / diluent paste (e.g., non-reactive diluent and some additional resin), and D) hardener paste. Pastes A, C, and D can be produced in bulk by blending the raw materials in the specified order using a blade high-speed mixer, e.g., a Cowles or Ross model. The composition of these pastes can be kept constant. The anti-wear agent base includes anti-wear agents such as titanium dioxide, graphene, graphite, and finely divided barium sulfate. In some embodiments, the anti-wear agents are added one at a time to the specified amount of paste A. This may induce a spike in the viscosity of the resulting mill base, so intermittent addition of paste C to the mill base may be preferred. In some embodiments, for every 1 / 3 addition of base B to the mill base, 1 / 3 of paste C is added. During the addition of base B, the powders can be pre-blended at a blade speed not exceeding 600-800 rpm. Once base B is added and premixed, proceed to the milling stage, adjusting the blade speed to 2,500-3,000 rpm and allowing the duration of the milling step to not exceed 10-15 minutes depending on the batch size. The hollow ceramic spheres are added between or during the addition of bases B and C. The spheres are added and mixed at about 2000-3000 rpm to achieve good dispersion and minimize or avoid crushing of the spheres. In some embodiments, the efficiency of the milling step can be detected using a Hegman spread gauge. In some embodiments, when a rheology modifier is added to the composition, the temperature is kept between about 55-60°C. In some embodiments, maintaining the temperature in this range promotes the crystalline to amorphous phase change of the rheology modifier. In some embodiments, the final product is supplied via a two-component kit in the amount required by the end customer.
[0219] One or more embodiments of the present disclosure provide for coating a surface of a substrate with a pre-cured composition mixed with a curing agent (referred to herein as a curable composition). In some embodiments, this includes a) cleaning and drying the surface, b) optionally applying at least one primer coat to the surface, and c) applying at least one coat of the curable composition over the optional primer coat, and optionally applying at least one functional top coat to produce a cured coating. The substrate to be coated can be of various natures, such as metal (e.g., steel), ceramic, fiberglass, carbon fiber, wood, and plastic.
[0220] In some embodiments of the present disclosure, the substrate (after being coated) is for use in a wet environment. Such environments are environments in which the substrate periodically comes into contact with water. Examples of substrates include sensors for tracking water parameters (such as temperature, depth, salinity, dissolved gases, pH, etc. in marine, estuarine and coastal ecosystems, freshwater environments), automotive parts, agricultural equipment, aquaculture equipment, hydroelectric power generation equipment, and oil and gas industry equipment. Examples of marine equipment include boats, ships and vessels, particularly their hulls, ballast, and propellers, buoys, fish traps, underwater equipment (including underwater robotic equipment, sensors, etc.), submarines, etc. In some embodiments, the substrate comprises a marine device, preferably a hull or a propeller.
[0221] In some embodiments, the surface of the substrate to which the curable composition is applied is prepared by cleaning, drying, and polishing it. For example, the surface is first cleaned to be free of contaminants such as grease, oil, wax, or mold. In some embodiments, if the surface is polished, it is cleaned before polishing to avoid abrading contaminants into the surface. The surface is then dried as much as possible to help promote adhesion of the cured coating. The surface is then abraded and roughened, for example by polishing, especially in the case of hardwoods and non-porous surfaces, because this also promotes adhesion of the cured coating. In other embodiments, the surface is prepared to be coated according to one of the following standards: SSPC-SP1, SSPC-SP2, SSPC-SP-5, SSPC-SP WJ-1 / NACE WJ-1, and / or SSPC-SP16.
[0222] The curable composition of the present disclosure can be applied to a substrate as follows: First, a substrate prepared as described above is provided. Then, optionally, a primer coating is applied onto the substrate, generally in one or two coats. One or more coats (preferably two or more) of the curable composition are applied onto any primer coating or onto the substrate to form a cured coating. In some embodiments, the coating is formed onto the primer coating. If a primer coating is used, the primer should be compatible with the curable composition so that the cured coating will adhere to the primer. In other embodiments, the coating is formed onto the substrate. Once formed onto the substrate, the cured coating can form a top coating (e.g., the cured coating is in direct contact with the environment) or the cured coating can form an undercoating to which a functional top coating can be applied. In some embodiments, the curable compositions of the present disclosure may be applied to a substrate in accordance with one or more of the following standards or methods: SSPC-SP-1, SSPC-SP-11, SSPC-SP-5, SSPC-SP WJ-1 / NACE WJ-1, SSPC-SP WJ-2 / NACE WJ-2, SSPC-SP WJ-3 / NACE WJ-3, SSPC-SP WJ-4 / NACE WJ-4, SSPC-VIS-3, SSPC-VIS-4, SSPC-PA-2 LEVEL 3, SSPC-GUIDE 15, SSPC-GUIDE 6, NACE RPO 287-95, ASTM D-4285, Occupational Safety and Health (Part 11, Canada Labour Code; Policy Volume Of The Tb Manual); Canadian Environmental Protection Act, and Canadian Fishery Act.
[0223] In some embodiments of the present disclosure, the curable composition is applied to a substrate uncured (or partially cured) and then cured via reaction with a curing agent to form a cured coating. The curable composition can be applied to the substrate by a variety of coating techniques, including painting, brushing, spraying, rolling or dipping the composition onto the substrate. The cured coating formed from the curable composition can be about 1 μm to about 400 μm thick, preferably about 100 μm to about 200 μm thick, or about 150 μm to about 200 μm thick.
[0224] Coating composition and coating thereof
[0225] Described herein is a coating composition comprising a solvent-based epoxy resin, a diluent, an adhesion promoter, an anti-settling rheology modifier, an anti-sag rheology modifier, and a ceramic performance additive comprising hollow ceramic spheres. In one or more embodiments, the composition further comprises one or a combination of a dispersant, an anti-wear agent, an anti-foam agent, a curing catalyst, and a hardener composition. In one or more embodiments, the coating composition seeks to provide a cured coating useful for reducing underwater radiated noise (compared to a control). In one or more embodiments, the coating composition seeks to provide a pre-cured composition that can be applied to a ship's hull and otherwise form a cured coating useful for reducing underwater radiated noise (compared to a control) from a ship's engine into a marine environment.
[0226] In one or more embodiments, the ceramic performance additive comprising hollow ceramic spheres attempts to provide sound deadening properties to coatings formed from the pre-cured composition. In one or more embodiments, the amount of spheres in the pre-cured coating is about 25-35 wt %, based on the total weight %. In one or more embodiments, the weight % of about 25 wt % to about 35 wt % is a sufficient amount of hollow ceramic spheres to provide a coating that reduces radiated noise (relative to a control) by about 5 dB to about 7 dB / 100 μm. In one or more embodiments, a coating comprising hollow ceramic spheres at a weight % between about 25 wt % to about 35 wt % was applied at a coating thickness of about 200 to about 300 micrometers, reducing radiated noise by up to about 9 dB.
[0227] In one or more embodiments, if the amount of spheres in the pre-cured coating is about 45% or more by weight based on the total weight %, there may not be enough resin in the composition. In other cases, the resulting cured coating may be more permeable to water, ions, or other components in the marine environment, and may therefore be more susceptible to corrosion, blistering, and / or delamination. In one or more embodiments, the pre-cured composition includes at least 15% to 20% by weight of a solvent-based resin, based on the weight % of Part A, to promote the formation of a less permeable cured coating that may have an underwater life of at least 5 years.
[0228] In one or more embodiments, the curable composition including the pre-curing composition is applied to a substrate such as the hull of a marine vessel. In one or more embodiments, the curable composition is applied at a coating thickness of about 200 to about 500 micrometers, or about 200 to about 500 micrometers, or about 200 to 300 micrometers, or about 250 micrometers. The curable composition can be applied directly to the substrate, which can be metal (e.g., steel). The curable composition can be applied to a primed substrate, where the substrate has already been coated with a primer. Sufficient substrate or overcoat adhesion of the curable composition and the resulting cured coating to the substrate or primed substrate reduces delamination and / or peeling of the cured coating from the substrate. In one or more embodiments, this adhesion is promoted by including an adhesion promoter in the pre-curing composition. In one or more embodiments, this adhesion is promoted by combining the adhesion promoter and the curing agent in the curable composition. In one or more embodiments, the curing agent includes an amine curing agent, such as an amine modified phanelkamine.
[0229] In one or more embodiments, a pre-cured composition comprising hollow ceramic spheres is provided to form a cured undercoating. In one or more embodiments, the cured undercoating exhibits sound deadening properties but does not exhibit topcoat properties such as foul release, surface leveling, etc. In one or more embodiments, a topcoat is applied over the cured undercoating or curable undercoating. In one or more embodiments, the topcoat applied to the cured undercoating or curable undercoating is selected to provide antifouling / foul release properties. In one or more embodiments, the topcoat applied to the curable undercoat or cured undercoat may include coatings such as those described in International Application PCT / CA2021 / 000042, entitled "Composition For A Coating, Coatings and Methods Thereof." In one or more embodiments, the epoxy / NH ratio in the curable composition between the epoxy resin and the amine curing agent is about 1.2 to about 1.4. In one or more embodiments, an epoxy / NH ratio of about 1.2 to about 1.4 in the curable composition provides a sufficient recoat adhesion window of about 4 to 72 hours during which the applied topcoat can adhere well to the undercoat (e.g., have good recoat adhesion).
[0230] In one or more embodiments, the anti-settling rheology modifier of the pre-cured composition attempts to reduce settling of at least the hollow ceramic spheres. By reducing settling, the anti-settling rheology modifier of the pre-cured composition can increase the shelf life, or long-term storage stability, of the pre-cured coating. In one or more embodiments, the anti-sag rheology modifier of the pre-cured composition attempts to reduce or prevent sagging of the curable composition while it is being applied to a substrate, such as a boat hull. Without this, the thickness of the final cured coating may be unevenly distributed across the coated substrate, which may reduce the sound-deadening properties of the coating.
[0231] In one or more embodiments, the solvent-based epoxy resin comprises bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin, cycloaliphatic polyglycidyl ether modified epoxy resin, cycloaliphatic polyglycidyl ether resin having a viscosity in the range of about 350 to about 550 cps, cycloaliphatic polyglycidyl ether modified resin having a viscosity in the range of about 400 to about 1000 cps, aliphatic glycidyl ether modified epoxy resin having a viscosity in the range of about 800 to about 1000 cps, or combinations thereof. In one or more embodiments, the adhesion promoter comprises an alkoxylated silane that is optionally reactive in epoxy polymerization, a hydroxyphenyl-benzotriazole, a hydroxyphenyl-triazine, or combinations thereof. In one or more embodiments, the anti-settling rheology modifier comprises fumed silica, fumed silica surface-modified with a silane, fumed silica surface-modified with dimethyldichlorosilane, aluminum phyllosilicate clay, organically modified derivatives of aluminum phyllosilicate clay, organically modified bentonite clay, organically modified montmorillonite clay, or combinations thereof. In one or more embodiments, the anti-sag rheology modifier comprises a polyamide wax, a micronized polyamide wax, a micronized organically modified polyamide wax, a micronized organically modified polyamide wax derivative, or a combination thereof. In one or more embodiments, the hollow ceramic spheres have a particle size of about 20 μm to about 40 μm, or about 25 μm to about 35 μm. In one or more embodiments, the curing agent comprises a phenalkamine, an amine-modified phenalkamine, or a combination thereof.
[0232] In one or more embodiments, the coating formed from the pre-cured composition has a flexural strength, as measured in a cylindrical bend test, of at least 10 mm, or at least 8 mm, or at least 6 mm.
[0233] Described herein is a coating composition comprising a solvent-based epoxy resin, a diluent, an adhesion promoter comprising a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof, a rheology modifier comprising an anti-settling rheology modifier, an anti-sag rheology modifier, a surface leveling rheology modifier, or a combination thereof, and a ceramic performance additive comprising hollow ceramic spheres, non-hollow ceramic particles, or a combination thereof. In one or more embodiments, the composition further comprises one or a combination of a dispersant, an anti-wear agent, an anti-foam agent, a weathering additive, a curing catalyst, and a hardener composition. In one or more embodiments, the coating composition seeks to provide a cured coating useful for reducing cavitation (relative to a control). In one or more embodiments, the coating composition seeks to provide a curable composition or a pre-cured composition that forms a cured coating that adheres well to a metal substrate, such as a copper metal substrate or an aluminum substrate. In one or more embodiments, the coating compositions provide a pre-cured composition that can be applied to a marine propeller to form a cured coating that is useful for reducing cavitation that would otherwise occur when the marine propeller is in use. In one or more embodiments, the coating compositions provide a pre-cured composition that can be applied to a propeller to form a cured coating that, when applied to the propeller, increases the RMP so that the propeller can rotate before cavitation occurs.
[0234] In one or more embodiments, the ceramic performance additive, including hollow ceramic spheres, non-hollow ceramic particles, or a combination thereof, attempts to provide hardness properties to a coating formed from a pre-cured composition. In one or more embodiments, the ceramic performance additive attempts to provide a coating formed from a pre-cured composition having a hardness of at least 5H, or a hardness of about 6H to about 8H, or about 8H, as measured according to ASTM D3363. In one or more embodiments, the hollow ceramic spheres include hollow ceramic spheres having a particle size of about 10 μm to about 40 μm. In one or more embodiments, the non-hollow ceramic particles include titanium oxide, fumed silica, brown aluminum (III) oxide, fused aluminum (III) oxide, titanium alloys (such as titanium carbonitride, titanium carbide, etc.), or combinations thereof. In one or more embodiments, the hardness of a coating formed from a pre-cured composition correlates with the cavitation resistance of the coating. That is, the harder the coating is mechanically, the less likely it is to experience cavitation (e.g., by the blister test or boiling test of Example 3). In one or more embodiments, the cured coatings having a hardness of at least 5H and up to 8H retain structural integrity over their service life, reduce erosion and slit cavitation, and through reduced cavitation, maintain the energy efficiency and low noise profile of the vessels to which the coatings are applied.
[0235] In one or more embodiments, the surface leveling rheology modifier of the pre-cured composition attempts to provide a cured coating formed from the pre-cured composition that is relatively smooth and / or exhibits low roughness. In one or more embodiments, the smoothed surface of the coating formed from the pre-cured composition also correlates with the cavitation resistance of the coating. That is, the smoother the coating surface, the less likely cavitation will occur (e.g., fewer nucleation sites or defects on the coating surface). In one or more embodiments, the anti-settling rheology modifier of the pre-cured composition attempts to reduce settling of at least the ceramic performance additive. By reducing settling, the anti-settling rheology modifier of the pre-cured composition can increase the shelf life, or long-term storage stability, of the pre-cured coating. In one or more embodiments, the anti-sag rheology modifier of the pre-cured composition attempts to reduce or prevent sagging of the curable composition while the curable composition is being applied to a substrate, such as a boat propeller. Without this, the thickness of the final cured coating may be unevenly distributed across the coated substrate, which may reduce the sound-deadening properties of the coating.
[0236] In one or more embodiments, the pre-cured composition is applied to a metal substrate, or a primed metal substrate. In one or more embodiments, the metal substrate, or the primed metal substrate, is a ship's propeller. In one or more embodiments, when the pre-cured composition is applied to a metal substrate, it is a one-coat system. In one or more embodiments, the pre-cured composition in a one-coat system is formulated to include primer coating properties (e.g., through the use of an adhesion promoter). In one or more embodiments, the curable composition is applied at a coating thickness of about 100 to about 200 micrometers, or about 125 to about 150 micrometers. In one or more embodiments, where the pre-cured composition is applied to a primed metal substrate, it is a two-coat system, with the second coat being a primer coating. In one or more embodiments, the pre-cured composition is applied to a metal substrate, or a primed metal substrate, as a top coating. In one or more embodiments, as a top coating, the pre-cured composition is formulated to exhibit anti-wear properties, anti-corrosion properties, and / or anti-fouling / foul release properties. In one or more embodiments, when the pre-cured composition is applied directly to a metal substrate, the pre-cured composition includes at least one of an adhesion promoter including a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof. In one or more embodiments, when the pre-cured composition is applied to a primed metal substrate, both the primer coating and the pre-cured composition applied to the metal substrate include at least one of an adhesion promoter including a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof.
[0237] In one or more embodiments, the adhesion promoter, including a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof, attempts to provide a cured coating formed from the curable composition or pre-cured composition that adheres well to a metal substrate, such as a copper metal substrate or an aluminum substrate. Generally, coatings for use in wet environments tend not to adhere well to metal substrates, but in one or more embodiments, by using an adhesion promoter, including a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof, a cured coating formed from the curable composition or pre-cured composition adheres to a metal substrate, such as a copper metal substrate or an aluminum substrate, with a dry adhesion of about 3 to about 15 MPa, or about 3 to about 10 MPa, or about 3 to about 5 MPa, and / or a wet adhesion of about 4 to about 15 MPa, or about 4 to about 10 MPa, or about 5 to about 7 MPa.
[0238] In one or more embodiments, the primer coating used in the two-coat system is any primer compatible with the pre-cured composition. In one or more embodiments, the primer coating used in the two-coat system is any primer compatible with the pre-cured composition including an adhesion promoter including a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof. In one or more embodiments, the primer coating of the two-coat system includes a reaction product of a primer coating composition and a curing agent. In one or more embodiments, the primer coating composition includes an epoxy resin or a urethane resin. In one or more embodiments, the primer coating composition includes an epoxy resin, such as the solvent-based epoxy resins described herein. In one or more embodiments, the primer coating composition includes at least 10 wt. % of an epoxy resin. In one or more embodiments, the primer coating composition includes an adhesion promoter including a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof. In one or more embodiments, the primer coating composition includes a filler to create micro-roughness in the dry primer and induce gas-liquid barrier properties. In one or more embodiments, the filler includes magnesium silicate (talc), wollastonite, barium sulfate, fumed silica, or combinations thereof in an amount of 30 wt.% or greater based on the total weight of the formulation, for example, to promote micro-roughness of the primer coating surface, thereby promoting adhesion with a top coating formed from the pre-cured composition.
[0239] In one or more embodiments, the solvent-based epoxy resin comprises a hybrid epoxy siloxane resin. In one or more embodiments, the dry adhesion promoter, the dry / wet adhesion promoter, and / or the wet adhesion promoter are non-reactive, reactive in epoxy resin polymerization, reactive with the substrate, and / or reactive with metal oxides, or a combination thereof. In one or more embodiments, the dry adhesion promoter is non-reactive, reactive in epoxy resin polymerization, reactive with the substrate, and / or reactive with metal oxides. In one or more embodiments, the dry adhesion promoter comprises an alkoxylated silane. In one or more embodiments, the dry adhesion promoter comprises an epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, or a combination thereof. In one or more embodiments, the wet adhesion promoter is reactive with the substrate. In one or more embodiments, the wet adhesion promoter comprises a metal-doped phosphosilicate. In one or more embodiments, the wet adhesion promoter comprises a strontium phosphosilicate, a zinc phosphosilicate, a calcium strontium aluminum zinc orthophosphate silicate hydrate, or a combination thereof. In one or more embodiments, the dry / wet adhesion promoter is non-reactive, reactive with the substrate, and / or reactive with metal oxides. In one or more embodiments, the dry / wet adhesion promoter comprises modified polyester, modified polyester oligomer, polyacrylic acid, polyacrylate, benzotriazole, polymer or prepolymer containing mercaptan, or combinations thereof. In one or more embodiments, the anti-settling rheology modifier comprises fumed silica, fumed silica surface modified with silane, fumed silica surface modified with dimethyldichlorosilane, or combinations thereof. In one or more embodiments, the anti-sag rheology modifier comprises castor oil wax, organically modified castor oil derivative wax, polyamide wax, micronized polyamide wax, micronized organically modified polyamide wax, micronized organically modified polyamide wax derivative, or combinations thereof. In one or more embodiments, the anti-sag rheology modifier comprises castor oil wax, organically modified castor oil derivative wax, or combinations thereof.In one or more embodiments, the surface leveling rheology modifier comprises a polyether siloxane copolymer. In one or more embodiments, the hollow ceramic spheres have a particle size of about 10 μm to about 40 μm, about 20 μm to about 40 μm, or about 25 μm to about 35 μm, or about 10 μm to about 15 μm, or about 12 μm. In one or more embodiments, the non-hollow ceramic particles comprise titanium oxide, fumed silica, brown aluminum (III) oxide, fused aluminum (III) oxide, titanium alloy, or combinations thereof. In one or more embodiments, the non-hollow ceramic particles comprise titanium alloy, titanium carbonitride, titanium carbide, or combinations thereof.
[0240] In one or more embodiments, the coating formed from the pre-cured composition has a flexural strength of at least 10 mm, or at least 8 mm, or at least 6 mm, as measured in a cylindrical bend test. In one or more embodiments, the combination of adhesion promoter and anti-wear agent, including graphite oxide, graphene, and multi-layer graphene flakes, contributes to the flexural strength.
[0241] As described herein, one or more embodiments of the present disclosure seek to provide pre-cured compositions that can be used to form coatings that exhibit improved intercoat adhesion, flexural strength of at least 10 mm, reduced noise emissions, and / or improved hardness (as indicated by improved scratch resistance) compared to a control.
[0242] In one or more embodiments, the inclusion of an adhesion promoter in the pre-cured composition improves the flexibility and / or intercoat adhesion of the cured coating obtained from the composition. In some embodiments, the inclusion of an adhesive improves the cohesion of the cured coating, where cohesion refers to the mechanical strength of a single cured coating layer and how well it resists peeling, compressive, bending, or any other damaging forces. In one or more embodiments, the adhesion promoter is included in an amount sufficient to provide a coating formed from the composition with an intercoat adhesion of at least 5 MPa, or between about 5 MPa and about 10 MPa, as measured according to ASTM D4541, or a flexural strength of at least 10 mm, or at least 8 mm, or about 6 mm, as measured in a cylindrical bend test.
[0243] In one or more embodiments, the inclusion of hollow ceramic spheres in the pre-cured composition improves sound deadening properties and / or improves the hardness of the cured coating (relative to a control). In one or more embodiments, the hollow ceramic spheres are included in an amount sufficient to provide a coating formed from the composition with reduced noise emissions (e.g., sound deadening properties) of about 1 dB to about 50 dB, or about 40 dB, or about 20 dB, or about 15 dB per about 100 μm of coating thickness at frequencies in the range of about 1000 Hz or less, or about 100 to about 1000 Hz, or about 100 to about 400 Hz, or a hardness of at least 5H, or about 6H to about 8H, as measured according to ASTM D3363.
[0244] As mentioned above, underwater radiated noise (URN) includes sounds that are radiated at frequencies below 100 Hz and may extend up to 10,000 Hz, with the primary sources being engines and propellers of marine vessels. In some cases, engines may generate low frequencies (e.g., 100-1000 Hz) that may disturb larger marine animals, and in some cases, propellers may generate high frequencies (e.g., 1000-10,000 Hz) that may disturb smaller marine organisms. Assume that low frequency sounds have long wavelengths (e.g., the wavelength of a 100 Hz sound is about 3,000,000 m, and the wavelength of a 1000 Hz sound is about 300,000 m). Therefore, it may be difficult for a relatively thin sound deadening material to interact with and reduce low frequency noise with such a large wavelength. However, in one or more embodiments of the present disclosure, a pre-cured composition is provided that includes a sufficient amount of hollow ceramic spheres to provide a coating having reduced noise emissions at frequencies of about 1000 Hz or less and at coating thicknesses of less than 500 μm (e.g., 200 μm) (e.g., about 1 dB to about 50 dB per about 100 μm coating thickness when measured on a 3 mm thick cold rolled steel sheet compared to an uncoated 3 mm thick cold rolled steel sheet).
[0245] Furthermore, as discussed above, the inclusion of hollow ceramic spheres in the pre-cured composition may improve at least the scratch resistance, due to the high hardness of the ceramic spheres (e.g., 7 on the Mohs scale). However, a relatively high loading of solid components in the coating composition may cause the resulting cured coating to be brittle and inflexible (e.g., when the weight ratio of solids to binder is greater than 2). Furthermore, in one or more embodiments, a pre-cured composition is provided that includes a sufficient amount of hollow ceramic spheres to provide a coating having a hardness of at least 5H as measured according to ASTM D3363, and a sufficient amount of adhesion promoter to provide a flexural strength of at least 10 mm. Thus, in one or more embodiments, the pre-cured composition provides a coating that is highly scratch resistant (measured by hardness) while also being flexible. In one or more embodiments, a pre-cured composition is provided that includes a weight ratio of solids to binder greater than 2 (e.g., about 2.3) while still being flexible.
[0246] In one or more embodiments of the present disclosure, a solvent-based monomer composition comprising: (i) a low viscosity solvent-based monomer comprising an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 350 to about 550 cps, an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 400 to about 1000 cps, an epoxy-functional monomer modified with an aliphatic glycidyl ether having a viscosity in the range of about 800 to about 1000 cps, or a combination thereof; (ii) a diluent comprising a reactive diluent, a non-reactive diluent, or a combination thereof that is reactive in the polymerization of the solvent-based monomer, wherein the reactive diluent comprises butyl glycidyl ether, alkyl (C12-C14) glycidyl ether, or a combination thereof, and the non-reactive diluent comprises benzyl alcohol, xylene, methyl acetate, or a combination thereof; and (iii) a solvent-based monomer composition comprising an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 350 to about 550 cps, an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 400 to about 1000 cps, or a combination thereof, (iv) a coating thickness of about 100 mm or less at a frequency of about 1000 Hz or less when measured on a 3 mm thick cold rolled steel panel compared to an uncoated 3 mm thick cold rolled steel panel; and hollow ceramic spheres in an amount sufficient to provide a coating formed from the composition having a reduced noise emission of about 1 dB to about 50 dB per μm, the hollow ceramic spheres including spheres having a particle size of about 20 μm to about 40 μm, or about 25 μm to about 35 μm, and present in a range of about 30% to about 70% by weight, or about 35% to about 65% by weight, or about 30% to about 50% by weight, or about 35% to about 50% by weight, or about 45% to about 70% by weight, or about 50% to about 65% by weight.In one or more embodiments, the composition further comprises a rheology modifier, such as an aluminum phyllosilicate clay; an organically modified derivative of an aluminum phyllosilicate clay; an organically modified bentonite clay; an organically modified montmorillonite clay, such as Claytone-HY® or Claytone-APA®; a micronized organically modified polyamide wax derivative, such as Crayvallac Super®; a micronized barium sulfate, such as VB Techno®; a microcrystalline magnesium silicate, such as Talc Silverline 202® or Mistron 002®; or a combination thereof. In one or more embodiments, the composition further comprises a polymeric dispersant, such as a polymeric non-ionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof, the dispersant comprising ADDITOL VXW 6208® (polymeric non-ionic dispersant), K-SPERSE A504 (polymeric non-ionic dispersant), MULTIWET EF-LQ-AP® (polymeric non-ionic dispersant), or a combination thereof. In one or more embodiments, the composition further comprises an anti-wear agent, the anti-wear agent comprising graphene nanoplatelets, titanium dioxide, microcrystalline magnesium silicate, micronized barium sulfate, or a combination thereof. In one or more embodiments, the composition further comprises an anti-foaming agent, such as a polymeric anti-foaming agent, the anti-foaming agent comprising BYK-066 N, BYK-1790, or a combination thereof.In one or more embodiments, the composition further comprises a weathering additive, the weathering additive being 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2®), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900®), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400®), or a combination thereof. In one or more embodiments, the composition further comprises a curing catalyst, the curing catalyst comprising 2,4,6-tris[(dimethylamino)methyl]phenol. In one or more embodiments, the composition further comprises a hardener composition, the hardener composition comprising a hardener and optionally a diluent, the hardener being reactive in curing the composition to form a coating that is resistant to at least 50 passes of organic solvent abrasion as measured according to ASTM D1640. In one or more embodiments, the curing agent comprises an amine curing agent, an amide curing agent, or a combination thereof, such as phenalkamine, amine modified phenalkamine, phenalkamide, amine modified phenalkamide, polyamidoamine, modified polyamidoamine, or a combination thereof. In one or more embodiments, the diluent comprises a non-reactive diluent, such as methyl acetate, xylene, or a combination thereof. In one or more embodiments, the composition is used to form a coating on a substrate that is a marine vessel, such as a boat or ship surface. In one or more embodiments, the composition is used to reduce underwater radiated noise.
[0247] In one or more embodiments of the present disclosure, a solvent-based monomer composition may be used that comprises: (i) a solvent-based monomer comprising an epoxy-functional epoxide siloxane monomer as described herein, such as, for example, Silikopon® ED, Silikopon® EF, EPOSIL Resin 5550®, or a combination thereof; (ii) a diluent comprising a reactive diluent, a non-reactive diluent, or a combination thereof that is reactive in the polymerization of the solvent-based monomer, wherein the reactive diluent comprises an epoxy-functional polydimethylsiloxane and the non-reactive diluent comprises xylene, methyl acetate, or a combination thereof; (iii) an adhesion promoter in an amount sufficient to provide a coating formed from the composition having an intercoat adhesion of at least 5 MPa as measured according to ASTM D4541, or a flexural strength of at least 10 mm as measured in a cylindrical bend test, the adhesion promoter comprising an epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, or a combination thereof; and (iv) an adhesion promoter comprising an epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, or a combination thereof, as measured according to ASTM D4541. and hollow ceramic spheres in an amount sufficient to provide a coating formed from the composition having a hardness of at least 5H as measured according to D3363, the hollow ceramic spheres comprising spheres having a particle size of from about 10 μm to about 15 μm, or about 12 μm, and present in a range of from about 5% to about 20% by weight, or from about 10% to about 20% by weight, or from about 10% to about 18% by weight, or from about 10% to about 15% by weight. In one or more embodiments, the composition further comprises a rheology modifier, such as an organically modified castor oil, such as Thixatrol ST®, fumed silica, fumed silica surface modified with dimethyldichlorosilane, such as Cab-O-Sil TS-610®, microcrystalline magnesium silicate, such as Talc Silverline 202® or Mistron 002®, a polyether siloxane copolymer, such as TEGO® Glide 410® (Evonik), or a combination thereof.In one or more embodiments, the composition further comprises a dispersant, such as a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof, where the dispersant comprises TEGO® Glide 410® (a polyether siloxane copolymer), or a combination thereof. In one or more embodiments, the composition further comprises an anti-wear agent, where the anti-wear agent comprises multi-layer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, or a combination thereof. In one or more embodiments, the composition further comprises an anti-foaming agent, such as a polymeric anti-foaming agent, where the anti-foaming agent comprises BYK-066 N, BYK-1790, or a combination thereof. In one or more embodiments, the composition further comprises a weathering additive, the weathering additive being 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2®), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900®), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400®), or combinations thereof. In one or more embodiments, the composition further comprises a hardener composition comprising a hardener and optionally a diluent, the hardener being reactive in hardening the composition to form a coating having resistance to organic solvent abrasion of at least 50 passes as measured according to ASTM D1640. In one or more embodiments, the hardener comprises a silamine hardener, such as aminopropyltriethoxysilane. In one or more embodiments, the curing agent composition further comprises a curing catalyst, the curing catalyst comprising 2,4,6-tris[(dimethylamino)methyl]phenol.In one or more embodiments, the composition is used to form a coating on a substrate that is the surface of a marine device such as a sensor or a propeller, hi one or more embodiments, the composition is used to impart scratch resistance.
[0248] As described herein: 1. A coating composition comprising: A solvent-based monomer; A diluent; an adhesion promoter in an amount sufficient to provide a coating formed from the composition having an intercoat adhesion of at least 5 MPa as measured in accordance with ASTM D4541, or a flexural strength of at least 10 mm as measured in a cylindrical bend test; and a sufficient amount of hollow ceramic spheres to provide a coating formed from the composition that has reduced noise emissions of about 1 dB to about 50 dB per about 100 μm of coating thickness at frequencies of about 1000 Hz or less, as compared to an uncoated 3 mm thick cold rolled steel sheet, or has a hardness of at least 5H, as measured in accordance with ASTM D3363. 2. The composition of claim 1, wherein the solvent-based monomer comprises an allyl-functional monomer, an amino-functional monomer, a maleimide-functional monomer, a cyanate-functional monomer, an epoxy-functional monomer, a furan-functional monomer, a vinyl ester-functional monomer, or a combination thereof. 3. The composition according to claim 1, wherein the solvent-based monomer comprises a solvent-based prepolymer, such as an allyl-functional prepolymer, an amino-functional prepolymer, a polyester prepolymer, a bismaleimide prepolymer, a cyanate ester-functional prepolymer, an epoxy-functional prepolymer, a furan-functional prepolymer, a phenol-based prepolymer, a polyurea prepolymer, a polyurethane prepolymer, a silicone prepolymer, or a vinyl ester-functional prepolymer. 4. The solvent-based monomer comprises an epoxy-functional monomer, the epoxy-functional monomer being: bisphenol diglycidyl ether, Epoxy-functional monomers modified with alicyclic polyglycidyl ethers, Epoxy-functional monomers modified with aliphatic glycidyl ethers, Epoxy-functional epoxide siloxane monomers, reaction products of epichlorohydrin with one or more of hydroxyl-functional aromatic compounds, alcohols, thiols, acids, acid anhydrides, cycloaliphatic and aliphatic compounds, polyfunctional amines, and amine-functional aromatic compounds; reaction products of the oxidation of unsaturated alicyclic compounds, or The composition according to any one of items 1 to 3, comprising these combinations. 5. The solvent-based monomer comprises an epoxy-functional monomer, the epoxy-functional monomer being: bisphenol diglycidyl ether, Epoxy-functional epoxide siloxane monomers, Epoxy-functional monomers modified with alicyclic polyglycidyl ethers, an epoxy-functional monomer modified with an aliphatic glycidyl ether, or The composition according to any one of items 1 to 4, comprising these combinations. 6. The composition according to item 4 or 5, wherein the bisphenol diglycidyl ether is derived from bisphenol A, bisphenol F, bisphenol S, or a combination thereof. 7. The composition according to any one of items 4 to 6, wherein the epoxy-functional epoxide siloxane monomer comprises an epoxide backbone that comprises siloxane or polysiloxane side chains, e.g., the epoxide backbone is a polyether backbone, and / or the siloxane or polysiloxane side chains are linear, branched, or crosslinked. 8. The composition according to claim 7, wherein at least one of the siloxane or polysiloxane side chains is a crosslinked silicone resin. 9. The composition according to any one of items 4 to 8, wherein the epoxy-functional epoxide siloxane monomer comprises a reaction product of an isocyanate oligomer and / or a polyurethane oligomer, a silane oligomer, and an epoxy oligomer. 10. The composition according to any one of claims 7 to 9, wherein the epoxy-functional epoxide siloxane monomer comprises an epoxy-functional epoxide siloxane prepolymer. 11. The composition according to any one of paragraphs 7 to 10, wherein the epoxy-functional epoxide siloxane monomer comprises a 3-ethylcyclohexyl epoxy copolymer modified with dimethylsiloxane side chains, an epoxy bisphenol A (2,2-bis(4'-glycidyloxyphenyl)propane) modified with polydimethylsiloxane side chains, a siloxane-modified hybrid epoxy resin, a silicone epoxide resin, an epoxy-functional epoxide backbone functionalized with a crosslinked silicone resin containing terminal alkoxy groups, or a combination thereof. 12. The composition according to any one of paragraphs 7 to 11, wherein the epoxy-functional epoxide siloxane monomer comprises Silikopon® ED, Silikopon® EF, EPOSIL Resin 5550®, or a combination thereof. 13. The composition according to any one of items 1 to 12, wherein the solvent-based monomer is a low-viscosity solvent-based monomer, for example, a low-viscosity solvent-based monomer having a viscosity in the range of about 200 to about 1500 cps, or about 300 to about 1000 cps. 14. The composition according to item 13, wherein the low viscosity solvent-based monomer comprises an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 350 to about 550 cps, an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 400 to about 1000 cps, an epoxy-functional monomer modified with an aliphatic glycidyl ether having a viscosity in the range of about 800 to about 1000 cps, or a combination thereof. 15. The composition according to item 13 or 14, wherein the low viscosity solvent-based monomer comprises DLVE (registered trademark)-52 (ultra-low viscosity epoxy resin modified with alicyclic polyglycidyl ether epoxy resin), DLVE (registered trademark)-18 (low viscosity epoxy resin modified with alicyclic polyglycidyl ether epoxy resin), DER (registered trademark) 353 (C12 to C14 aliphatic glycidyl ether modified bisphenol A / F epoxy resin), or a combination thereof. 16. The composition according to any one of items 1 to 12, wherein the mixture of the solvent-based monomer and the diluent has a viscosity in the range of about 200 to about 3500 cps, or about 300 to about 3500 cps. 17. The composition according to any one of items 1 to 16, wherein the solvent-based monomer is present in an amount ranging from about 5% by weight to about 40% by weight, or from about 5% by weight to about 35% by weight, or from about 5% by weight to about 30% by weight. 18. The composition of any one of the preceding claims, wherein the diluent comprises a reactive diluent that is reactive in the polymerization of solvent-based monomers, a non-reactive diluent, or a combination thereof. 19. The composition of claim 18, wherein the reactive diluent comprises poly[(phenyl glycidyl ether)-co-formaldehyde], alkyl (C12-C14) glycidyl ether (e.g., EPODIL 748®), phenyl glycidyl ether, alkenyl-substituted phenyl glycidyl ether (e.g., Ultra Lite 513®), butyl glycidyl ether (e.g., Epodil 741®), 2-ethylhexyl glycidyl ether, o-cresol glycidyl ether, cycloaliphatic glycidyl ether, 1,2-epoxy-3-phenoxypropane, epoxy-functional polydimethylsiloxane (e.g., Tegomer E-SI 2330®, BYK Silclean 3701®), silicone amine (e.g., Silamine D2 EDA, Silamine D208 EDA), or a combination thereof. 20. The composition according to item 18 or 19, wherein the reactive diluent comprises butyl glycidyl ether, alkyl (C12-C14) glycidyl ether, epoxy-functional polydimethylsiloxane, or a combination thereof. 21. The composition according to any one of items 18 to 20, wherein the reactive diluent is present in an amount ranging from about 1% by weight to about 15% by weight, or from about 1% by weight to about 10% by weight, or from about 5% by weight to about 10% by weight. 22. The composition according to any one of paragraphs 17 to 21, wherein the non-reactive diluent comprises xylene, cyclohexane, toluene, methyl acetate, tert-butyl acetate, nonylphenol, cyclohexane dimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol (e.g., LIPOXOL 200, LIPOXOL 400 LIPOXOL 600), propylene glycol, phenol, methyl styrenated phenol (e.g., KUMANOX-3114 (registered trademark)), styrenated phenol (e.g., KUMANOX-3111F (registered trademark)), C12 to C37 ether (e.g., NACOL ETHER 6 (registered trademark), NACOL ETHER 8 (registered trademark)), low viscosity hydrocarbon resin (e.g., EPODIL LV5 (registered trademark)), aryl polyoxyethylene ether (e.g., Pycal 94 (registered trademark)), or a combination thereof. 23. The composition of any one of paragraphs 17 to 22, wherein the non-reactive diluent comprises benzyl alcohol, xylene, methyl acetate, or a combination thereof. 24. The composition according to any one of items 17 to 23, wherein the non-reactive diluent is present in an amount ranging from about 1% by weight to about 20% by weight, or from about 1% by weight to about 10% by weight, or from about 5% by weight to about 20% by weight. 25. The composition of any one of paragraphs 1 to 24, wherein the diluent comprises about 10% by weight of volatile organic compounds, or 10% by weight or less of volatile organic compounds. 26. The composition of any one of the preceding claims, wherein the adhesion promoter comprises an alkoxylated silane that is optionally reactive in the polymerization of solvent-based monomers. 27. The composition of any one of the preceding claims, wherein the adhesion promoter comprises an epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, or a combination thereof. 28. The composition according to any one of the preceding claims, wherein the adhesion promoter comprises 3-(2,3-epoxypropoxy)propyltrimethoxysilane, glycidoxypropyltrimethoxysilane, aminopropyltriethoxysilane, 3-aminopropyltriethoxysilane, a secondary aminobissilane, or a combination thereof. 29. The composition according to any one of the preceding claims, wherein the adhesion promoter is present in an amount ranging from about 0.1% to about 5% by weight, or from about 0.1% to about 1% by weight, or from about 1% to about 5% by weight. 30. The composition of any one of paragraphs 1 to 29, wherein a sufficient amount of the adhesion promoter provides a coating formed from the composition having an intercoat adhesion of about 5 MPa to about 10 MPa as measured according to ASTM D4541, or a flexural strength of at least 8 mm or about 6 mm as measured in a cylindrical bend test. 31. The composition according to any one of items 1 to 30, wherein the hollow ceramic spheres include spheres having a particle size of about 20 μm to about 40 μm, or about 25 μm to about 35 μm. 32. The composition according to item 31, wherein the hollow ceramic spheres are present in a range of about 30% to about 70% by weight, or about 35% to about 65% by weight, or about 30% to about 50% by weight. 33. The composition of claim 32, wherein the hollow ceramic spheres comprise Zeeospheres® G 600 hollow ceramic spheres, W410® hollow ceramic spheres, W610® hollow ceramic spheres, or a combination thereof. 34. The composition of any one of paragraphs 1 to 30, wherein the hollow ceramic spheres include spheres having a particle size of about 10 μm to about 15 μm, or about 12 μm. 35. The composition according to item 34, wherein the hollow ceramic spheres are present in a range of about 5% by weight to about 20% by weight, or about 10% by weight to about 20% by weight, or about 10% by weight to about 18% by weight, or about 10% by weight to about 15% by weight. 36. The composition of claim 35, wherein the hollow ceramic spheres comprise Zeeospheres® N-200PC hollow ceramic spheres, W210® hollow ceramic spheres, or a combination thereof. 37. The composition according to any one of paragraphs 1 to 36, wherein a sufficient amount of hollow ceramic spheres provide a coating formed from the composition having a reduced noise emission of about 1 dB to about 20 dB, or about 15 dB, per about 100 μm of coating thickness, or a hardness of about 6H to about 8H, for noise in the range of about 100 to about 1000 Hz, or about 100 to about 400 Hz. 38. The composition according to any one of paragraphs 1 to 37, further comprising a rheology modifier, such as aluminum phyllosilicate clay, organically modified derivatives of aluminum phyllosilicate clay, organically modified bentonite clay, organically modified montmorillonite clay, such as Claytone-HY (registered trademark) or Claytone-APA (registered trademark), organically modified castor oil, such as Thixatrol ST (registered trademark), micronized organically modified polyamide wax derivatives, such as Crayvallac Super (registered trademark), fumed silica, fumed silica surface-modified with dimethyldichlorosilane, such as Cab-0O-Sil TS-610 (registered trademark), micronized barium sulfate, such as VB Techno (registered trademark), microcrystalline magnesium silicate, such as Talc Silverline 202 (registered trademark) or Mistron 002 (registered trademark), polyether siloxane copolymer, such as TEGO (registered trademark) Glide 410 (registered trademark) (Evonik), or a combination thereof. 39. The composition according to item 38, wherein the rheology modifier is present in the range of about 0.3% by weight to about 5% by weight, or about 0.3% by weight to about 3% by weight, or about 0.3% by weight to about 1.5% by weight. 40. The composition according to any one of the preceding claims, further comprising a dispersant. 41. The composition according to paragraph 40, wherein the dispersant comprises a polymeric dispersant, such as a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof. 42. The dispersant is selected from the group consisting of ADDITOL VXW 6208® (polymeric non-ionic dispersant), K-SPERSE A504® (polymeric non-ionic dispersant), Disperbyk 140® (polymeric ionic dispersant, alkyl ammonium salt of acidic polymer), MULTIWET EF-LQ-AP® (polymeric non-ionic dispersant), HPERMER KD6-LQ-MV® (polymeric non-ionic dispersant blend), ECO NatraSense 125 MBAL-LQ-AP® (non-ionic alcohol ethoxylate dispersant), BRIJ-03-LQ-AP® (non-ionic alkyl polyglycol ether dispersant), SP BRIJ 02 MBAL LQ-AP® (non-ionic alkyl polyglycol ether dispersant), ANTI-TERRA-204® (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers Item 40 or 41, comprising TEGO Dispers 670 (polymeric nonionic dispersant), TEGO Dispers 1010 (polymeric nonionic dispersant), TEGO Glide 410 (polyether siloxane copolymer), or a combination thereof. 43. The composition according to any one of items 40 to 42, wherein the dispersant is present in an amount ranging from about 0.1% by weight to about 5% by weight, or from about 0.1% by weight to about 4% by weight, or from about 0.1% by weight to about 3% by weight, or from about 0.1% by weight to about 2% by weight, or from about 0.1% by weight to about 1% by weight. 44. The composition according to any one of the preceding claims, further comprising an anti-wear agent, such as graphite oxide, multi-layer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or a combination thereof. 45. The composition according to paragraph 44, wherein the antiwear agent is present in the range of about 0.5% by weight to about 5% by weight, or about 0.5% by weight to about 2% by weight. 46. The composition according to any one of the preceding claims, further comprising an antifoaming agent, such as a polymeric antifoaming agent. 47. The composition according to paragraph 46, wherein the antifoaming agent comprises a silicone oligomer, such as a polysiloxane oligomer. 48. The composition according to paragraph 46 or 47, wherein the antifoaming agent comprises BYK-066 N, BYK-1790, or a combination thereof, optionally present in a range of about 0.1% by weight to about 5% by weight, or about 0.1% by weight to about 1% by weight, or about 1% by weight to about 5% by weight. 49. The composition according to any one of the preceding claims, further comprising a weather resistance additive. 50. The weathering additive is 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2®), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900®), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400 (registered trademark), or a combination thereof, optionally present in a range of about 0.5% to about 5% by weight, or about 1% to about 5% by weight. 51. The composition according to any one of the preceding claims, further comprising a curing catalyst. 52. The composition of claim 51, wherein the curing catalyst comprises 2,4,6-tris[(dimethylamino)methyl]phenol. 53. The composition according to any one of items 1 to 52, comprising about 80% to about 90% by weight of solids. 54. The composition according to any one of claims 1 to 53, further comprising a hardener composition, the hardener composition comprising a hardener and optionally a diluent, the hardener being reactive in curing the composition and forming a coating having resistance to at least 50 passes of organic solvent polishing as measured according to ASTM D1640. 55. The composition of claim 54, wherein the curing agent is an amine curing agent, an amide curing agent, or a combination thereof, such as phenalkamine, amine-modified phenalkamine, phenalkamide, amine-modified phenalkamide, polyamidoamine, organically modified polyamidoamine, or a combination thereof; or a silamine curing agent, such as aminopropyltriethoxysilane; optionally present in a range of about 70% to about 100% by weight, or about 70% to about 90% by weight of the curing agent composition. 56. The composition according to paragraph 54 or 55, wherein the diluent comprises a non-reactive diluent such as methyl acetate, xylene, or a combination thereof, optionally present in a range of about 1 to 30% by weight of the hardener composition, for example, xylene is present in a range of about 1% to about 5% by weight and methyl acetate is present in a range of about 10% to about 25% by weight. 57. A coating comprising a reaction product of the coating composition according to any one of items 1 to 53 and a curing agent. 58. Use of the coating composition according to any one of items 1 to 56 for forming a coating on a substrate. 59. The use according to paragraph 58, wherein the substrate is the surface of a marine vessel, such as a boat or ship, or the surface of a marine device, such as a sensor or a propeller. 60. Use of a coating comprising a reaction product of the coating composition according to any one of items 1 to 53 and a curing agent for reducing underwater radiated noise. 61. Use of a coating comprising a reaction product of the coating composition according to any one of items 1 to 53 and a curing agent on a substrate to impart scratch resistance. 62. A method for forming a coating composition, comprising: mixing together a solvent-based monomer, a diluent, an adhesion promoter, and hollow ceramic spheres; forming a coating composition; A method comprising: 63. The method of claim 62, further comprising mixing a rheology modifier, a dispersant, an antifoaming agent, and / or an anti-wear agent. 64. When the antiwear agent is mixed, the solvent-based monomer, the diluent, the adhesion promoter, and the hollow ceramic spheres are mixed together; mixing together a solvent-based monomer, a diluent, and an adhesion promoter; grinding the antiwear agent; and mixing the ground antiwear agent with a mixture of a solvent-based monomer, a diluent, and an adhesion promoter; mixing hollow ceramic spheres; Item 64. The method of item 63, comprising:
[0249] This specification also describes the following: 1. A coating composition comprising: A solvent-based monomer; A diluent; an adhesion promoter in an amount sufficient to provide a coating formed from the composition having a substrate adhesion of at least 3 MPa as measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa as measured according to ASTM D4541, or a recoat adhesion window of at least 4 hours as measured according to ASTM D3359; a rheology control agent in an amount sufficient to provide a coating formed from the composition having anti-settling, anti-sag or surface leveling properties; a ceramic performance additive in an amount sufficient to provide a coating formed from the composition having reduced noise emissions of about 2 dB to about 10 dB per about 100 μm of coating thickness at frequencies from about 10 Hz to about 10 kHz, as compared to a 3 mm thick cold rolled steel plate coated with a coating that does not contain the ceramic performance additive, or a hardness of at least 5H, as measured in accordance with ASTM D3363, as measured on a 3 mm thick cold rolled steel plate. A coating composition comprising: 2. The composition of claim 1, wherein the solvent-based monomer comprises an allyl-functional monomer, an amino-functional monomer, a maleimide-functional monomer, a cyanate-functional monomer, an epoxy-functional monomer, a furan-functional monomer, a vinyl ester-functional monomer, or a combination thereof. 3. The composition according to claim 1 or 2, wherein the solvent-based monomer comprises a solvent-based prepolymer, such as an allyl-functional prepolymer, an amino-functional prepolymer, a polyester prepolymer, a bismaleimide prepolymer, a cyanate ester-functional prepolymer, an epoxy-functional prepolymer, a furan-functional prepolymer, a phenolic prepolymer, a polyurea prepolymer, a polyurethane prepolymer, a silicone prepolymer, or a vinyl ester-functional prepolymer. 4. The solvent-based monomer comprises an epoxy-functional monomer, the epoxy-functional monomer being: bisphenol diglycidyl ether, Epoxy-functional monomers modified with alicyclic polyglycidyl ethers, Epoxy-functional monomers modified with aliphatic glycidyl ethers, Epoxy-functional epoxide siloxane monomers, reaction products of epichlorohydrin with one or more of hydroxyl-functional aromatic compounds, alcohols, thiols, acids, acid anhydrides, cycloaliphatic and aliphatic compounds, polyfunctional amines, and amine-functional aromatic compounds; reaction products of the oxidation of unsaturated alicyclic compounds, or The composition according to any one of items 1 to 3, comprising these combinations. 5. The solvent-based monomer comprises an epoxy-functional monomer, the epoxy-functional monomer being: bisphenol diglycidyl ether, Epoxy-functional epoxide siloxane monomers, Epoxy-functional monomers modified with alicyclic polyglycidyl ethers, an epoxy-functional monomer modified with an aliphatic glycidyl ether, or The composition according to any one of items 1 to 4, comprising these combinations. 6. The composition according to any one of items 1 to 5, wherein the bisphenol diglycidyl ether is derived from bisphenol A, bisphenol F, bisphenol S, or a combination thereof. 7. The composition according to any one of items 1 to 6, wherein the epoxy-functional epoxide siloxane monomer comprises an epoxide backbone that comprises siloxane or polysiloxane side chains, e.g., the epoxide backbone is a polyether backbone, and / or the siloxane or polysiloxane side chains are linear, branched, or crosslinked. 8. The composition according to any one of items 1 to 7, wherein at least one of the siloxane or polysiloxane side chains is a crosslinked silicone resin. 9. The composition according to any one of claims 1 to 8, wherein the epoxy-functional epoxide siloxane monomer comprises a reaction product of an isocyanate oligomer and / or a polyurethane oligomer, a silane oligomer, and an epoxy oligomer. 10. The composition according to any one of claims 1 to 9, wherein the epoxy-functional epoxide siloxane monomer comprises an epoxy-functional epoxide siloxane prepolymer. 11. The composition according to any one of paragraphs 1 to 10, wherein the epoxy-functional epoxide siloxane monomer comprises a 3-ethylcyclohexyl epoxy copolymer modified with dimethylsiloxane side chains, an epoxy bisphenol A (2,2-bis(4'-glycidyloxyphenyl)propane) modified with polydimethylsiloxane side chains, a siloxane-modified hybrid epoxy resin, a silicone epoxide resin, an epoxy-functional epoxide backbone functionalized with a crosslinked silicone resin containing terminal alkoxy groups, or a combination thereof. 12. The composition according to any one of the preceding claims, wherein the epoxy-functional epoxide siloxane monomer comprises Silikopon® ED, Silikopon® EF, EPOSIL Resin 5550®, or a combination thereof. 13. The composition according to any one of items 1 to 12, wherein the solvent-based monomer is a low-viscosity solvent-based monomer, for example, a low-viscosity solvent-based monomer having a viscosity in the range of about 200 to about 1500 cps, or about 300 to about 1000 cps. 14. The composition according to any one of items 1 to 13, wherein the low-viscosity solvent-based monomer comprises an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 350 to about 550 cps, an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 400 to about 1000 cps, an epoxy-functional monomer modified with an aliphatic glycidyl ether having a viscosity in the range of about 800 to about 1000 cps, or a combination thereof. 15. The composition according to any one of items 1 to 14, wherein the low viscosity solvent-based monomer comprises DLVE (registered trademark)-52 (ultra-low viscosity epoxy resin modified with alicyclic polyglycidyl ether epoxy resin), DLVE (registered trademark)-18 (low viscosity epoxy resin modified with alicyclic polyglycidyl ether epoxy resin), DER (registered trademark) 353 (C12 to C14 aliphatic glycidyl ether modified bisphenol A / F epoxy resin), or a combination thereof. 16. The composition according to any one of items 1 to 15, wherein the mixture of the solvent-based monomer and the diluent has a viscosity in the range of about 200 to about 3500 cps, or about 300 to about 3500 cps. 17. The composition according to any one of items 1 to 16, wherein the solvent-based monomer is present in a range of about 5% by weight to about 35% by weight, or about 5% by weight to about 30% by weight, or about 10% by weight to about 30% by weight, or about 15% by weight to about 20% by weight, based on the weight percent of part A, or about 5% by weight to about 25% by weight, or about 5% by weight to about 20% by weight, or about 10% by weight to about 20% by weight, or about 15% by weight to about 20% by weight, based on the total weight percent. 18. The composition of any one of the preceding claims, wherein the diluent comprises a reactive diluent that is reactive in the polymerization of solvent-based monomers, a non-reactive diluent, or a combination thereof. 19. The composition according to any one of the preceding claims, wherein the reactive diluent comprises poly[(phenyl glycidyl ether)-co-formaldehyde], alkyl (C12-C14) glycidyl ether (e.g., EPODIL 748®), phenyl glycidyl ether, alkenyl-substituted phenyl glycidyl ether (e.g., Ultra Lite 513®), butyl glycidyl ether (e.g., Epodil 741®), 2-ethylhexyl glycidyl ether, o-cresol glycidyl ether, cycloaliphatic glycidyl ether, 1,2-epoxy-3-phenoxypropane, epoxy-functional polydimethylsiloxane (e.g., Tegomer E-SI 2330®, BYK Silclean 3701®), silicone amine (e.g., Silamine D2 EDA, Silamine D208 EDA), or a combination thereof. 20. The composition of any one of the preceding claims, wherein the reactive diluent comprises butyl glycidyl ether, alkyl (C12-C14) glycidyl ether, epoxy-functional polydimethylsiloxane, or a combination thereof. 21. The composition according to any one of items 1 to 20, wherein the reactive diluent is present in a range of about 1% by weight to about 15% by weight, or about 1% by weight to about 10% by weight, or about 1% by weight to about 5% by weight, based on the weight percent or total weight percent of part A. 22. The composition according to any one of paragraphs 1 to 21, wherein the non-reactive diluent is xylene, cyclohexane, toluene, methyl acetate, methyl ethyl ketone, tert-butyl acetate, nonylphenol, cyclohexane dimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol (e.g., LIPOXOL 200, LIPOXOL 400 LIPOXOL 600), propylene glycol, phenol, methyl styrenated phenol (e.g., KUMANOX-3114 (registered trademark)), styrenated phenol (e.g., KUMANOX-3111F (registered trademark)), C12 to C37 ether (e.g., NACOL ETHER 6 (registered trademark), NACOL ETHER 8 (registered trademark)), low viscosity hydrocarbon resin (e.g., EPODIL LV5 (registered trademark)), aryl polyoxyethylene ether (e.g., Pycal 94 (registered trademark)), or a combination thereof. 23. The composition of any one of paragraphs 1 to 22, wherein the non-reactive diluent comprises benzyl alcohol, xylene, methyl acetate, an ether, an aromatic solvent, or a combination thereof. 24. The composition according to any one of items 1 to 23, wherein the non-reactive diluent is present in a range of about 1% by weight to about 20% by weight, or about 1% by weight to about 10% by weight, or about 5% by weight to about 20% by weight, based on the weight percent of part A, or about 5% by weight to about 25% by weight, or about 5% by weight to about 20% by weight, or about 10% by weight to about 20% by weight, based on the total weight percent. 25. The composition of any one of paragraphs 1 to 24, wherein the diluent comprises about 10% by weight of volatile organic compounds, or 10% by weight or less of volatile organic compounds. 26. The composition according to any one of paragraphs 1 to 25, wherein the adhesion promoter comprises a silane promoter that is optionally reactive in the polymerization of solvent-based monomers; a dry adhesion promoter that is optionally reactive in the polymerization of solvent-based monomers, reactive with the substrate, and / or reactive with metal oxides; a wet adhesion promoter that is optionally reactive in the polymerization of solvent-based monomers, reactive with the substrate, and / or reactive with metal oxides; a dry / wet adhesion promoter that is optionally reactive, optionally reactive in the polymerization of solvent-based monomers, reactive with the substrate, and / or reactive with metal oxides; or a combination thereof. 27. The composition according to any one of the preceding claims, wherein the adhesion promoter comprises an alkoxylated silane, such as an epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, or a combination thereof; a modified polyester, such as a modified polyester having a sufficient hydroxyl number of about 30 mg to about 100 mg KOH / g, a polyacrylic acid, a modified polyester oligomer, a polyacrylate, a metal-doped phosphosilicate, a benzotriazole, a polymer or prepolymer comprising a mercaptan, or a combination thereof. 28. The composition according to any one of paragraphs 1 to 27, wherein the adhesion promoter comprises 3-(2,3-epoxypropoxy)propyltrimethoxysilane; glycidoxypropyltrimethoxysilane; aminopropyltriethoxysilane; 3-aminopropyltriethoxysilane; secondary aminobissilane; modified polyester such as Tego Addbond LTW-B (registered trademark), Tego Addbond 2220 ND (registered trademark); strontium phosphosilicate such as HALOX (registered trademark) SW-111; zinc calcium strontium aluminum orthophosphate silicate hydrate such as HEUCOPHOS (registered trademark) ZCP-Plus; zinc phosphosilicate such as InvoCor Cl-3315 (Invotec); alkyl-substituted hydroxylamine-substituted benzotriazole such as CCI-01 copper adhesion promoter; mercaptan-containing polymers or prepolymers such as CAPCURE (registered trademark) 3-800, CAPCURE (registered trademark) 40 SEC HV; or a combination thereof. 29. The composition according to any one of items 1 to 28, wherein the adhesion promoter is present in a range of about 1 wt% to about 10 wt%, or about 2 wt% to about 10 wt%, or about 2 wt% to about 8 wt%, based on the weight percent of part A, or about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1 wt%, or about 1 wt% to about 5 wt%, based on the total weight percent. 30. The composition of any one of paragraphs 1 to 29, wherein a sufficient amount of the adhesion promoter provides a coating formed from the composition having a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, or a recoat adhesion window of about 4 hours to about 72 hours, as measured according to ASTM D3359, or a combination thereof. 31. The composition of any one of the preceding claims, wherein the ceramic performance additive comprises a hollow ceramic and a non-hollow ceramic. 32. The composition according to any one of items 1 to 31, wherein the hollow ceramic comprises hollow ceramic spheres having a particle size of about 10 μm to about 40 μm, about 20 μm to about 40 μm, or about 25 μm to about 35 μm, or about 10 μm to about 15 μm, or about 12 μm. 33. The composition according to any one of items 1 to 32, wherein the hollow ceramic spheres have a particle size of about 20 μm to about 40 μm, or about 25 μm to about 35 μm, and the hollow ceramic spheres are present in a range of about 30 wt% to about 70 wt%, or about 35 wt% to about 65 wt%, or about 30 wt% to about 50 wt%, based on the weight% of part A, or in a range of about 15 wt% to about 50 wt%, or about 20 wt% to about 50 wt%, or about 20 wt% to about 45 wt%, or about 15 wt% to about 40 wt%, based on the weight% of part A or the total weight%. 34. The composition according to any one of items 1 to 33, wherein the hollow ceramic spheres are present in the range of about 5% by weight to about 70% by weight, about 15% by weight to about 70% by weight, about 25% by weight to about 70% by weight, about 35% by weight to about 70% by weight, about 40% by weight to about 70% by weight, or about 5% by weight to about 20% by weight, or about 10% by weight to about 20% by weight, or about 10% by weight to about 18% by weight, or about 10% by weight to about 15% by weight, based on the total weight percent, when the hollow ceramic spheres have a particle size of about 10 μm to about 15 μm, or about 15% by weight to about 40% by weight. 35. The composition of any one of paragraphs 1 to 34, wherein the hollow ceramic spheres comprise Zeeospheres® G 600 hollow ceramic spheres, W410® hollow ceramic spheres, W610® hollow ceramic spheres, Zeeospheres® N-200PC hollow ceramic spheres, W210® hollow ceramic spheres, W410® hollow ceramic spheres, W610® hollow ceramic spheres, or combinations thereof. 36. The composition according to any one of items 1 to 35, wherein the non-hollow ceramic comprises non-hollow ceramic particles having a particle size of about 0.1 μm to about 5 μm, about 0.5 μm to about 5 μm, or about 1 μm to about 5 μm, or about 2 μm to about 5 μm. 37. The composition according to any one of items 1 to 36, wherein the non-hollow ceramic particles are present in a range of about 10% by weight to about 50% by weight, or about 10% by weight to about 45% by weight, or about 15% by weight to about 40% by weight, based on the weight percent of part A, or in a range of about 5% by weight to about 40% by weight, or about 10% by weight to about 35% by weight, or about 20% by weight to about 35% by weight, or about 10% by weight to about 20% by weight, based on the total weight percent. 38. The composition of any one of paragraphs 1 to 37, wherein the non-hollow ceramic particles comprise titanium oxide, brown aluminum (III) oxide, fused aluminum (III) oxide, a titanium alloy, or a combination thereof. 39. The composition of any one of paragraphs 1 to 38, wherein a sufficient amount of the ceramic performance additive provides a coating formed from the composition having a reduced noise emission of about 3 dB to about 9 dB, or about 5 dB to about 7 dB, or a hardness of about 6H to about 8H, or about 8H, per about 100 μm of coating thickness. 40. The composition of any one of the preceding claims, wherein the rheology modifier comprises an anti-settling rheology modifier, an anti-sag rheology modifier, or a combination thereof. 41. The composition according to any one of paragraphs 1 to 40, wherein the rheology control agent comprises an aluminum phyllosilicate clay; an organically modified derivative of an aluminum phyllosilicate clay; an organically modified bentonite clay; an organically modified montmorillonite clay, such as Claytone-HY (registered trademark) or Claytone-APA (registered trademark); an organically modified castor oil derivative wax, such as Thixatrol ST (registered trademark); a micronized organically modified polyamide wax derivative, such as Crayvallac Super (registered trademark); a fumed silica, a fumed silica surface-modified with a silane, a fumed silica surface-modified with a dimethyldichlorosilane, such as Cab-O-Sil TS-610 (registered trademark); a micronized barium sulfate, such as VB Techno (registered trademark); a microcrystalline magnesium silicate, such as Talc Silverline 202 (registered trademark) or Mistron 002 (registered trademark); a polyether siloxane copolymer, such as TEGO (registered trademark) Glide 410 (registered trademark) (Evonik); or a combination thereof. 42. The composition according to any one of paragraphs 1 to 41, wherein the anti-settling rheology modifier comprises fumed silica, silane-surface-modified fumed silica, dimethyldichlorosilane-surface-modified fumed silica, aluminum phyllosilicate clay, an organically modified derivative of an aluminum phyllosilicate clay, an organically modified bentonite clay, an organically modified montmorillonite clay, or a combination thereof. 43. The composition of any one of the preceding claims, wherein the anti-sag rheology modifier comprises a micronized organically modified polyamide wax derivative, an organically modified castor oil derivative wax, or a combination thereof. 44. The composition according to any one of items 1 to 43, wherein the rheology modifier is present in a range of about 1 wt% to about 5 wt%, or about 1 wt% to about 3 wt%, or about 1 wt% to about 1.5 wt%, based on the weight percent of part A, or in a range of about 0.3 wt% to about 5 wt%, or about 0.3 wt% to about 3 wt%, or about 0.3 wt% to about 1.5 wt%, based on the total weight percent. 45. The composition according to any one of the preceding claims, wherein the anti-sag rheology modifier or anti-settling rheology modifier is present in a range of about 0.1% by weight to about 5% by weight, or about 0.3% by weight to about 3% by weight, or about 0.3% by weight to about 1.5% by weight, based on the total weight percent. 46. The composition according to any one of the preceding claims, further comprising a dispersant. 47. The composition of any one of the preceding claims, wherein the dispersant comprises a polymeric dispersant, such as a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof. 48. The dispersant is selected from the group consisting of ADDITOL VXW 6208® (polymeric non-ionic dispersant), K-SPERSE A504® (polymeric non-ionic dispersant), Disperbyk 140® (polymeric ionic dispersant, alkyl ammonium salt of acidic polymer), MULTIWET EF-LQ-AP® (polymeric non-ionic dispersant), HPERMER KD6-LQ-MV® (polymeric non-ionic dispersant blend), ECO NatraSense 125 MBAL-LQ-AP® (non-ionic alcohol ethoxylate dispersant), BRIJ-03-LQ-AP® (non-ionic alkyl polyglycol ether dispersant), SP BRIJ 02 MBAL LQ-AP® (non-ionic alkyl polyglycol ether dispersant), ANTI-TERRA-204® (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers Item 670 (polymeric nonionic dispersant), TEGO Disperse 1010 (polymeric nonionic dispersant), TEGO (registered trademark) Glide 410 (polyether siloxane copolymer), or a combination thereof. The composition according to any one of items 1 to 47. 49. The composition according to any one of items 1 to 48, wherein the dispersant is present in a range of about 0.1% by weight to about 2% by weight, or about 0.1% by weight to about 1.5% by weight, or about 0.1% by weight to about 1% by weight, based on the weight percent of part A, or in a range of about 0.1% by weight to about 5% by weight, or about 0.1% by weight to about 4% by weight, or about 0.1% by weight to about 3% by weight, or about 0.1% by weight to about 2% by weight, or about 0.1% by weight to about 1% by weight, based on the total weight percent. 50. The composition of any one of the preceding claims, further comprising an anti-wear agent, such as graphite oxide, multi-layer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or a combination thereof. 51. The composition according to any one of paragraphs 1 to 50, wherein the antiwear agent is present in a range of about 0.01% by weight to about 5% by weight, 0.05% by weight to about 5% by weight, 0.5% by weight to about 5% by weight, or about 0.5% by weight to about 2% by weight, based on the weight percent or total weight percent of part A. 52. The composition according to any one of the preceding claims, further comprising a hydrophobicity control additive, the hydrophobicity control additive comprising an epoxy-functional silane, an epoxy-functional polydialkylsiloxane, or a combination thereof. 53. The composition of any one of the preceding claims, wherein the hydrophobicity control additive comprises an epoxy-functional polydialkylsiloxane. 54. The composition of any one of the preceding claims, wherein the hydrophobicity control additive comprises an epoxy-functional polydialkylsiloxane. 55. The composition of any one of the preceding claims, wherein the epoxy-functional silane comprises glycidoxypropyltrimethoxysilane. 56. The composition according to any one of the preceding claims, further comprising an antifoaming agent, for example a polymeric antifoaming agent. 57. The composition according to any one of the preceding claims, wherein the antifoaming agent comprises a silicone-based oligomeric antifoaming agent, such as a polysiloxane oligomer. 58. The composition according to any one of paragraphs 1 to 57, wherein the antifoaming agent comprises BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airex 900, or a combination thereof, and is optionally present in a range of about 1 wt% to about 5 wt%, or about 1 wt% to about 3 wt%, or about 1 wt% to about 1.5 wt%, based on the weight percent of part A, or in a range of about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1 wt%, or about 1 wt% to about 5 wt%, based on the total weight percent. 59. The composition according to any one of the preceding claims, further comprising a weather resistance additive. 60. The weathering additive is 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2®), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900®), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400 (registered trademark), or a combination thereof, optionally present in a range of about 0.5% by weight to about 5% by weight, or about 1% by weight to about 5% by weight. 61. The composition according to any one of the preceding claims, wherein the weathering additive is a wet / dry adhesion promoter. 62. The composition according to any one of the preceding claims, further comprising a curing catalyst. 63. The composition according to any one of the preceding claims, wherein the curing catalyst comprises 2,4,6-tris[(dimethylamino)methyl]phenol. 64. The composition according to any one of the preceding claims, comprising about 80% to about 90% by weight of solids. 65. The composition according to any one of the preceding claims, further comprising a hardener composition, the hardener composition comprising a hardener and optionally a diluent, the hardener being reactive in curing the composition and forming a coating having resistance to an organic solvent buffing treatment of at least 50 passes, or 50 to 80 passes, as measured according to ASTM D1640. 66. The composition according to any one of the preceding claims, wherein the curing agent is an amine curing agent, an amide curing agent, or a combination thereof, such as phenalkamine, amine-modified phenalkamine, phenalkamide, amine-modified phenalkamide, polyamidoamine, organically modified polyamidoamine, or a combination thereof; or a silamine curing agent, such as aminopropyltriethoxysilane, triaminofunctional propyltrimethoxysilane; or a combination thereof; optionally present in a range of about 40% to about 100% by weight, or 40% to about 90% by weight, or about 70% to about 100% by weight, or about 70% to about 90% by weight of the curing agent composition. 67. The composition according to any one of paragraphs 1 to 66, wherein the diluent comprises a non-reactive diluent, such as xylene, benzyl alcohol, methyl ethyl ketone, methyl acetate, an ether, an aromatic solvent, or a combination thereof, optionally present in a range of about 1 to 30% by weight of the hardener composition, and optionally, the xylene is present in a range of about 1% by weight to about 5% by weight, and the methyl acetate is present in a range of about 10% by weight to about 25% by weight. 68. A coating comprising a reaction product of the coating composition according to any one of items 1 to 64 and a curing agent. 69. A coating comprising a reaction product of the coating composition according to any one of items 1 to 64 and the curing agent composition according to any one of items 65 to 67. 70. A coating according to paragraph 68 or 69, having a flexural strength of at least 10 mm as measured in a cylindrical bend test. 71. The coating of any one of paragraphs 68 to 70, having a flexural strength of at least 8 mm, or at least 6 mm, as measured in a cylindrical bend test. 72. The coating of any one of paragraphs 68 to 71, having a substrate adhesion of at least 3 MPa as measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa as measured according to ASTM D4541, or a recoat adhesion window of at least 4 hours as measured according to ASTM D3359, or a combination thereof. 73. The coating of any one of paragraphs 68 to 72, having a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, or a recoat adhesion window of about 4 hours to about 72 hours, as measured according to ASTM D3359, or a combination thereof. 74. The coating of any one of paragraphs 68 to 73, having reduced noise emissions of about 2 dB to about 10 dB per about 100 μm of coating thickness at frequencies from about 10 Hz to about 10 kHz, as compared to a 3 mm thick cold rolled steel sheet coated with a coating that does not contain the ceramic performance additive, or a hardness of at least 5H as measured according to ASTM D3363, as measured on a 3 mm thick cold rolled steel sheet. 75. The coating of any one of paragraphs 68 to 74, having a reduced noise emission of about 3 dB to about 9 dB, or about 5 dB to about 7 dB, per about 100 μm of coating thickness, or a hardness of about 6H to about 8H, or about 8H. 76. A coating composition comprising: A solvent-based epoxy resin; A diluent; An adhesion promoter; an anti-settling rheology modifier; an anti-sag rheology modifier; a ceramic performance additive comprising hollow ceramic spheres; A coating composition comprising: 77. The composition according to item 76, wherein the epoxy resin comprises a bisphenol A epoxy resin, a bisphenol F epoxy resin, a bisphenol S epoxy resin, an alicyclic polyglycidyl ether modified epoxy resin, an alicyclic polyglycidyl ether resin having a viscosity in the range of about 350 to about 550 cps, an alicyclic polyglycidyl ether modified resin having a viscosity in the range of about 400 to about 1000 cps, an aliphatic glycidyl ether modified epoxy resin having a viscosity in the range of about 800 to about 1000 cps, or a combination thereof. 78. The composition according to any one of paragraphs 76 to 77, wherein the epoxy resin is present in an amount of about 5 to about 30% by weight, or about 5 to about 20% by weight, or about 15 to about 20% by weight, or about 10% by weight to about 20% by weight, based on the weight percent of part A. 79. The composition of any one of paragraphs 76 to 78, wherein the diluent comprises a reactive diluent that is reactive in epoxy polymerization, a non-reactive diluent, or a combination thereof. 80. The composition of any one of paragraphs 76 to 79, wherein the reactive diluent comprises butyl glycidyl ether, C12 to C14 aliphatic glycidyl ether, phenyl glycidyl ether, alkenyl substituted phenyl glycidyl ether, 2-ethylhexyl glycidyl ether, o-cresol glycidyl ether, cycloaliphatic glycidyl ether, 1,2-epoxy-3-phenoxypropane, epoxy functional polydimethylsiloxane, or a combination thereof. 81. The composition of any one of paragraphs 76 to 80, wherein the reactive diluent comprises butyl glycidyl ether, a C12 to C14 aliphatic glycidyl ether, or a combination thereof. 82. The composition according to any one of paragraphs 76 to 81, wherein the reactive diluent is present in a range of about 1% by weight to about 15% by weight, or about 1% by weight to about 10% by weight, or about 5% by weight to about 10% by weight, or about 1% by weight to about 5% by weight, based on the weight percent of part A, or in a range of about 1% by weight to about 10% by weight, or about 2% by weight to about 8% by weight, based on the total weight percent. 83. The composition of any one of paragraphs 76 to 82, wherein the non-reactive diluent comprises xylene, cyclohexane, toluene, methyl acetate, methyl ethyl ketone, tert-butyl acetate, nonylphenol, cyclohexanedimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol, propylene glycol, phenol, or a combination thereof. 84. The composition of any one of paragraphs 76 to 83, wherein the non-reactive diluent comprises benzyl alcohol, xylene, methyl ethyl ketone, methyl acetate, an ether, an aromatic solvent, or a combination thereof. 85. The composition of any one of paragraphs 76 to 84, wherein the non-reactive diluent is present in a range of about 1% by weight to about 20% by weight, or about 1% by weight to about 10% by weight, or about 5% by weight to about 20% by weight, based on the weight percent or total weight percent of part A. 86. The composition of any one of paragraphs 76 to 85, wherein the adhesion promoter comprises an alkoxylated silane, a hydroxyphenyl-benzotriazole, a hydroxyphenyl-triazine, or a combination thereof, which is optionally reactive in epoxy polymerization. 87. The composition of any one of paragraphs 76 to 86, wherein the adhesion promoter comprises an epoxy functional alkoxylated silane, an amino functional alkoxylated silane, a hydroxyphenylbenzotriazole, a hydroxyphenyltriazine, or a combination thereof. 88. The adhesion promoter is 3-(2,3-epoxypropoxy)propyltrimethoxysilane, glycidoxypropyltrimethoxysilane, aminopropyltriethoxysilane, 3-aminopropyltriethoxysilane, secondary aminobissilane, 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl esters with 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2®), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900 (registered trademark), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400 (registered trademark)), or a combination thereof. 89. The composition of any one of paragraphs 76 to 88, wherein the adhesion promoter is present in a range of about 0.1 wt % to about 5 wt %, or about 0.1 wt % to about 1 wt %, or about 1 wt % to about 5 wt %, based on the weight % or total weight % of part A. 90. The composition of any one of paragraphs 76 to 89, wherein the anti-settling rheology modifier comprises silica, clay, or a combination thereof. 91. The composition of any one of paragraphs 76 to 90, wherein the anti-settling rheology modifier comprises fumed silica, silane-surface-modified fumed silica, dimethyldichlorosilane-surface-modified fumed silica, aluminum phyllosilicate clay, an organically modified derivative of an aluminum phyllosilicate clay, an organically modified bentonite clay, an organically modified montmorillonite clay, or a combination thereof. 92. The composition according to any one of paragraphs 76 to 91, wherein the anti-settling rheology modifier is present in a range of about 0.1% by weight to about 5% by weight, or about 0.3% by weight to about 3% by weight, or about 0.3% by weight to about 2% by weight, based on the weight percent of part A, or in a range of about 0.1% by weight to about 2% by weight, or about 0.2% by weight to about 1.5% by weight, or about 0.3% by weight to about 1.3% by weight, based on the total weight percent. 93. The composition of any one of paragraphs 76 to 92, wherein the anti-sag rheology modifier comprises a wax, a micronized wax, or a combination thereof. 94. The composition of any one of paragraphs 76 to 93, wherein the anti-sag rheology modifier comprises polyamide wax, micronized polyamide wax, micronized organically modified polyamide wax, micronized organically modified polyamide wax derivative, castor oil wax, organically modified castor oil derivative wax, or a combination thereof. 95. The composition of any one of paragraphs 76 to 94, wherein the anti-sag rheology modifier comprises a polyamide wax, a micronized polyamide wax, a micronized organically modified polyamide wax, a micronized organically modified polyamide wax derivative, or a combination thereof. 96. The composition of any one of paragraphs 76 to 95, wherein the anti-sag rheology modifier is present in a range of about 0.1 wt % to about 1.5 wt %, or about 0.1 wt % to about 1 wt %, or about 0.1 wt % to about 0.5 wt %, based on the weight % or total weight % of part A. 97. The composition of any one of paragraphs 76 to 96, wherein the ceramic performance additive comprises hollow ceramic spheres having a particle size of about 20 μm to about 40 μm, or about 25 μm to about 35 μm. 98. The composition of any one of paragraphs 76 to 97, wherein the hollow ceramic spheres are present in a range of about 20% by weight to about 40% by weight, or about 25% by weight to about 35% by weight, based on the weight percent or total weight percent of part A. 99. The composition of any one of paragraphs 76 to 98, wherein the hollow ceramic spheres comprise Zeeospheres® G 600 hollow ceramic spheres, W410® hollow ceramic spheres, W610® hollow ceramic spheres, or a combination thereof. 100. The composition according to any one of items 76 to 99, further comprising a dispersant. 101. The composition of any one of paragraphs 76 to 100, wherein the dispersant comprises a polymeric dispersant. 102. The composition of any one of paragraphs 76 to 101, wherein the dispersant comprises a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof. 103. The dispersant is selected from the group consisting of ADDITOL VXW 6208 (polymeric nonionic dispersant), K-SPERSE A504 (polymeric nonionic graphene dispersant), MULTIWET EF-LQ-AP (polymeric nonionic dispersant), HPERMER KD6-LQ-MV (polymeric nonionic dispersant blend), BRIJ-03-LQ-AP (nonionic alkyl polyglycol ether dispersant), SP BRIJ 02 MBAL LQ-AP (nonionic alkyl polyglycol ether dispersant), ANTI-TERRA-204 (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670 (polymeric nonionic dispersant), TEGO Dispers 1010 (polymeric nonionic dispersant), TEGO (registered trademark) Glide Item 76 to 102, comprising 410 (registered trademark) (polyether siloxane copolymer), or a combination thereof. 104. The composition according to any one of paragraphs 76 to 103, wherein the dispersant is present in a range of about 0.1% by weight to about 1.5% by weight, or about 0.1% by weight to about 1% by weight, or about 0.1% by weight to about 0.5% by weight, based on the weight percent or total weight percent of part A. 105. The composition according to any one of paragraphs 76 to 104, further comprising an antiwear agent. 106. The composition of any one of paragraphs 76 to 105, wherein the wear inhibitor comprises graphite oxide, graphene, multilayer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or a combination thereof. 107. The composition according to any one of paragraphs 76 to 106, wherein the antiwear agent is present in a range of about 0.01% by weight to about 1% by weight, or about 0.05% by weight to about 0.5% by weight, or about 0.05% by weight to about 0.8% by weight, based on the weight percent or total weight percent of part A. 108. The composition according to any one of claims 76 to 107, further comprising an antifoaming agent. 109. The composition of any one of paragraphs 76 to 108, wherein the defoamer comprises a polymeric defoamer. 110. The composition of any one of paragraphs 76 to 109, wherein the defoamer comprises a silicone-based oligomeric defoamer. 111. The composition of any one of paragraphs 76 to 110, wherein the defoamer comprises BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airex 900, or a combination thereof. 112. The composition according to any one of paragraphs 76 to 111, wherein the antifoaming agent is optionally in the range of about 0.1% by weight to about 5% by weight, or about 0.1% by weight to about 1.5% by weight, or about 0.3% by weight to about 1.2% by weight, or about 1% by weight to about 5% by weight, based on the weight percent or total weight percent of part A. 113. The composition according to any one of items 76 to 112, further comprising a curing catalyst. 114. The composition of any one of paragraphs 76 to 113, wherein the curing catalyst comprises 2,4,6-tris[(dimethylamino)methyl]phenol. 115. The composition according to any one of paragraphs 76 to 114, further comprising a hardener composition, the hardener composition comprising a hardener and optionally a diluent, the hardener being reactive in curing the composition to form a coating having resistance to an organic solvent buffing treatment of at least 50 passes, or 50 to 80 passes, as measured according to ASTM D1640. 116. The composition of any one of paragraphs 76 to 115, wherein the curing agent comprises an amine curing agent, an amide curing agent, or a combination thereof. 117. The composition of any one of paragraphs 76 to 116, wherein the curing agent comprises a phenalkamine, an amine-modified phenalkamine, a phenalkamide, an amine-modified phenalkamide, a polyamidoamine, an organically modified polyamidoamine, or a combination thereof. 118. The composition of any one of paragraphs 76 to 117, wherein the curing agent is present in an amount to provide an epoxy group / NH ratio of about 1.2 to about 1.4. 119. The composition of any one of paragraphs 76 to 118, wherein the hardener is present in a range of about 70% to about 100% by weight, or about 70% to about 90% by weight of the hardener composition. 120. The composition of any one of paragraphs 76 to 119, wherein the diluent comprises a non-reactive diluent. 121. The composition of any one of paragraphs 76 to 120, wherein the diluent comprises xylene, benzyl alcohol, methyl ethyl ketone, methyl acetate, an ether, an aromatic solvent, or a combination thereof. 122. The composition according to any one of paragraphs 76 to 121, wherein the diluent is present in the range of about 1 to 30% by weight, or about 5 to 25% by weight, about 10 to 25% by weight, or about 1 to 5% by weight of the hardener composition. 123. A coating comprising a reaction product of the coating composition according to any one of items 76 to 114 and a curing agent. 124. A coating comprising a reaction product of the coating composition according to any one of items 76 to 114 and the curing agent composition according to any one of items 115 to 122. 125. The coating of paragraph 123 or 124, further comprising a primer coating. 126. The coating of any one of paragraphs 123 to 125, further comprising a topcoat coating. 127. A coating according to any one of paragraphs 123 to 126, having a flexural strength of at least 10 mm as measured in a cylindrical bend test. 128. A coating according to any one of paragraphs 123 to 127, having a flexural strength of at least 8 mm, or at least 6 mm, as measured in a cylindrical bend test. 129. The coating of any one of paragraphs 123 to 128, having a substrate adhesion of at least 3 MPa as measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa as measured according to ASTM D4541, or a recoat adhesion window of at least 4 hours as measured according to ASTM D3359, or a combination thereof. 130. The coating of any one of paragraphs 123 to 129, having a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, or a recoat adhesion window of about 4 hours to about 72 hours, as measured according to ASTM D3359, or a combination thereof. 131. The coating of any one of paragraphs 123 to 130, having reduced noise emissions of about 2 dB to about 10 dB per about 100 μm of coating thickness at frequencies from about 10 Hz to about 10 kHz, as measured on a 3 mm thick cold rolled steel sheet, compared to a 3 mm thick cold rolled steel sheet coated with a coating that does not contain the ceramic performance additive. 132. The coating of any one of paragraphs 123 to 131 having reduced noise emissions of about 3 dB to about 9 dB, about 5 dB to about 9 dB, or about 5 dB to about 7 dB per about 100 μm of coating thickness. 133. Use of the coating composition according to any one of items 123 to 132 for forming a coating on a substrate. 134. The use according to paragraph 133, wherein the substrate is the surface of a marine vessel, such as a boat or ship, or the surface of a marine device, such as a sensor or a propeller. 135. The use according to any one of paragraphs 133 to 134, wherein the substrate is a surface of a hull of a marine vessel. 136. Use of a coating comprising a reaction product of a coating composition according to any one of paragraphs 76 to 114 and a curing agent for reducing underwater radiated noise. 137. Use of a coating comprising a reaction product of the coating composition according to any one of items 76 to 114 and the curing agent composition according to items 115 to 122 for reducing underwater radiated noise. 138. A coating composition comprising: A solvent-based epoxy resin; A diluent; an adhesion promoter comprising a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof; a rheology modifier comprising an anti-settling rheology modifier, an anti-sag rheology modifier, a surface leveling rheology modifier, or a combination thereof; a ceramic performance additive comprising hollow ceramic spheres, non-hollow ceramic particles, or a combination thereof; A coating composition comprising: 139. The composition according to paragraph 138, wherein the epoxy resin comprises a hybrid epoxy siloxane resin. 140. The composition of any one of paragraphs 138 to 139, wherein the epoxy resin is present in an amount of about 30 to about 55% by weight, or about 40 to about 50% by weight, based on part A. 141. The composition of any one of paragraphs 138 to 140, further comprising a hydrophobicity control additive, the hydrophobicity control additive comprising an epoxy-functional silane, an epoxy-functional polydialkylsiloxane, or a combination thereof. 142. The composition of any one of paragraphs 138 to 141, wherein the hydrophobicity control additive comprises an epoxy-functional polydialkylsiloxane. 143. The composition of any one of paragraphs 138 to 142, wherein the hydrophobicity control additive comprises an epoxy-functional polydialkylsiloxane. 144. The composition of any one of paragraphs 138 to 143, wherein the epoxy-functional silane comprises glycidoxypropyltrimethoxysilane. 145. The composition of any one of paragraphs 138 to 144, wherein the diluent comprises a non-reactive diluent. 146. The composition of any one of paragraphs 138 to 145, wherein the non-reactive diluent comprises xylene, cyclohexane, toluene, methyl acetate, methyl ethyl ketone, tert-butyl acetate, nonylphenol, cyclohexanedimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol, propylene glycol, phenol, or a combination thereof. 147. The composition of any one of paragraphs 138 to 146, wherein the non-reactive diluent comprises benzyl alcohol, xylene, methyl ethyl ketone, methyl acetate, an ether, or an aromatic solvent, or a combination thereof. 148. The composition according to any one of paragraphs 138 to 147, wherein the non-reactive diluent is present in a range of about 1% by weight to about 20% by weight, or about 1% by weight to about 10% by weight, or about 5% by weight to about 20% by weight, or about 5% by weight to about 15% by weight, based on the weight percent of part A, or in a range of about 1% by weight to about 25% by weight, or about 5% by weight to about 20% by weight, or about 5% by weight to about 15% by weight, based on the total weight percent. 149. The composition according to any one of claims 138 to 148, wherein the dry adhesion promoter, the dry / wet adhesion promoter, and / or the wet adhesion promoter is non-reactive, reactive in epoxy resin polymerization, reactive with the substrate, and / or reactive with metal oxides, or a combination thereof. 150. The composition according to any one of paragraphs 138 to 149, wherein the dry adhesion promoter is non-reactive, reactive in epoxy resin polymerization, reactive with the substrate, and / or reactive with metal oxides. 151. The composition of any one of paragraphs 138 to 150, wherein the dry adhesion promoter comprises an alkoxylated silane. 152. The composition of any one of paragraphs 138 to 151, wherein the dry adhesion promoter comprises an epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, or a combination thereof. 153. The composition of any one of paragraphs 138 to 152, wherein the dry adhesion promoter comprises 3-(2,3-epoxypropoxy)propyltrimethoxysilane, glycidoxypropyltrimethoxysilane, aminopropyltriethoxysilane, 3-aminopropyltriethoxysilane, a secondary aminobissilane, or a combination thereof. 154. The composition of any one of paragraphs 138 to 153, wherein the wet adhesion promoter is reactive with the substrate. 155. The composition of any one of paragraphs 138 to 154, wherein the wet adhesion promoter comprises a metal-doped phosphosilicate. 156. The composition of any one of paragraphs 138 to 155, wherein the wet adhesion promoter comprises strontium phosphosilicate, zinc phosphosilicate, calcium strontium aluminum zinc orthophosphate silicate hydrate, or a combination thereof. 157. The composition according to any one of paragraphs 138 to 156, wherein the dry / wet adhesion promoter is non-reactive, reactive with the substrate, and / or reactive with metal oxides. 158. The composition of any one of paragraphs 138 to 157, wherein the dry / wet adhesion promoter comprises a modified polyester, a modified polyester oligomer, a polyacrylic acid, a polyacrylate, a benzotriazole, a mercaptan-containing polymer or prepolymer, or a combination thereof. 159. The composition of any one of paragraphs 138 to 158, wherein the modified polyester comprises a modified polyester having a sufficient hydroxyl value of about 30 mg to about 100 mg KOH / g. 160. The composition of any one of paragraphs 138 to 159, wherein the benzotriazole comprises an alkyl-substituted hydroxylamine-substituted benzotriazole, a hydroxyphenylbenzotriazole, or a combination thereof. 161. The composition according to any one of paragraphs 138 to 160, wherein the dry adhesion promoter, the dry / wet adhesion promoter, and / or the wet adhesion promoter is a metal adhesion promoter. 162. The composition according to any one of paragraphs 138 to 161, wherein the dry adhesion promoter, the dry / wet adhesion promoter, and / or the wet adhesion promoter is a copper or aluminum adhesion promoter. 163. The composition of any one of paragraphs 138 to 162, wherein the adhesion promoter is present in a range of about 0.1 wt % to about 10 wt %, about 0.1 wt % to about 8 wt %, about 0.1 wt % to about 5 wt %, or about 0.1 wt % to about 1 wt %, or about 1 wt % to about 5 wt %, or about 1 wt % to about 8 wt %, based on the weight % or total weight % of part A. 164. The composition of any one of paragraphs 138 to 163, wherein the anti-settling rheology modifier comprises silica, clay, or a combination thereof. 165. The composition of any one of paragraphs 138 to 164, wherein the anti-settling rheology modifier comprises fumed silica, fumed silica surface-modified with silane, fumed silica surface-modified with dimethyldichlorosilane, or a combination thereof. 166. The composition of any one of paragraphs 138 to 165, wherein the anti-settling rheology modifier is present in a range of about 0.1% by weight to about 5% by weight, or about 0.3% by weight to about 3% by weight, or about 0.3% by weight to about 2% by weight, based on the weight percent or total weight percent of part A. 167. The composition of any one of paragraphs 138 to 166, wherein the anti-sag rheology modifier comprises a wax, a derivatized wax, or a combination thereof. 168. The composition of any one of paragraphs 138 to 167, wherein the anti-sag rheology modifier comprises castor oil wax, organically modified castor oil derivative wax, polyamide wax, micronized polyamide wax, micronized organically modified polyamide wax, micronized organically modified polyamide wax derivative, or a combination thereof. 169. The composition of any one of paragraphs 138 to 168, wherein the anti-sag rheology modifier comprises a castor oil wax, an organically modified castor oil derivative wax, or a combination thereof. 170. The composition of any one of paragraphs 138 to 169, wherein the anti-sag rheology modifier is present in the range of about 0.1 wt % to about 1.5 wt %, or about 0.1 wt % to about 1 wt %, or about 0.1 wt % to about 0.5 wt %, based on the weight % or total weight % of part A. 171. The composition of any one of paragraphs 138 to 170, wherein the surface leveling rheology modifier comprises a polyether siloxane copolymer. 172. The composition according to any one of paragraphs 138 to 171, wherein the surface leveling rheology modifier is present in a range of about 0.1 wt% to about 1.5 wt%, or about 0.1 wt% to about 1 wt%, or about 0.1 wt% to about 0.5 wt%, based on the weight percent or total weight percent of part A. 173. The composition according to any one of paragraphs 138 to 172, wherein the hollow ceramic comprises hollow ceramic spheres having a particle size of about 10 μm to about 40 μm, about 20 μm to about 40 μm, or about 25 μm to about 35 μm, or about 10 μm to about 15 μm, or about 12 μm. 174. The composition of any one of paragraphs 138 to 173, wherein the hollow ceramic spheres are present in the range of about 5% by weight to about 15% by weight. 175. The composition according to any one of paragraphs 138 to 174, wherein the non-hollow ceramic particles have a particle size of about 0.1 μm to about 5 μm, about 0.5 μm to about 5 μm, or about 1 μm to about 5 μm, or about 2 μm to about 5 μm. 176. The composition according to any one of paragraphs 138 to 175, wherein the non-hollow ceramic particles are present in a range of about 5% by weight to about 40% by weight, or about 10% by weight to about 35% by weight, or about 20% by weight to about 35% by weight, or about 10% by weight to about 20% by weight, based on the weight percent or total weight percent of part A. 177. The composition of any one of paragraphs 138 to 176, wherein the non-hollow ceramic particles comprise titanium oxide, fumed silica, brown aluminum (III) oxide, fused aluminum (III) oxide, a titanium alloy, or a combination thereof. 178. The composition of any one of paragraphs 138 to 177, wherein the non-hollow ceramic particles comprise a titanium alloy, titanium carbonitride, titanium carbide, or a combination thereof. 179. The composition according to any one of paragraphs 138 to 178, further comprising a dispersant. 180. The composition of any one of paragraphs 138 to 179, wherein the dispersant comprises a polymeric dispersant. 181. The composition of any one of paragraphs 138 to 180, wherein the dispersant comprises a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof. 182. The dispersant is selected from the group consisting of ADDITOL VXW 6208 (polymeric nonionic dispersant), K-SPERSE A504 (polymeric nonionic graphene dispersant), MULTIWET EF-LQ-AP (polymeric nonionic dispersant), HYPERMER KD6-LQ-MV (polymeric nonionic dispersant blend), BRIJ-03-Lam Q-AP (nonionic alkyl polyglycol ether dispersant), SP BRIJ 02 MBAL LQ-AP (nonionic alkyl polyglycol ether dispersant), ANTI-TERRA-204 (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670 (polymeric nonionic dispersant), TEGO Disperse 1010 (polymeric nonionic dispersant), TEGO (registered trademark) Glide Item 138 to 181, the composition according to any one of items 138 to 181, comprising 410 (registered trademark) (polyether siloxane copolymer), or a combination thereof. 183. The composition according to any one of paragraphs 138 to 182, wherein the dispersant is present in a range of about 0.1% by weight to about 1.5% by weight, or about 0.1% by weight to about 1% by weight, or about 0.1% by weight to about 0.5% by weight, based on the weight percent or total weight percent of part A. 184. The composition according to any one of paragraphs 138 to 183, further comprising an antiwear agent. 185. The composition of any one of paragraphs 138 to 184, wherein the wear inhibitor comprises graphite oxide, graphene, multilayer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or a combination thereof. 186. The composition according to any one of paragraphs 138 to 185, wherein the antiwear agent is present in a range of about 0.01% by weight to about 1% by weight, or about 0.05% by weight to about 0.5% by weight, or about 0.05% by weight to about 0.8% by weight, based on the total weight percent. 187. The composition according to any one of paragraphs 138 to 186, further comprising an antifoaming agent. 188. The composition of any one of paragraphs 138 to 187, wherein the defoamer comprises a polymeric defoamer. 189. The composition of any one of paragraphs 138 to 188, wherein the defoamer comprises a silicone-based oligomeric defoamer. 190. The composition of any one of paragraphs 138 to 189, wherein the antifoaming agent comprises BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airex 900, or a combination thereof. 191. The composition according to any one of paragraphs 138 to 190, wherein the antifoaming agent is optionally in the range of about 0.1% by weight to about 5% by weight, or about 0.1% by weight to about 1% by weight, or about 1% by weight to about 5% by weight, based on the weight percent or total weight percent of part A. 192. The composition according to any one of paragraphs 138 to 191, further comprising a weather resistance additive. 193. The composition of any one of paragraphs 138 to 192, wherein the weathering additive comprises a hydroxyphenylbenzotriazole, a hydroxyphenyltriazine, or a combination thereof. 194. A weathering additive is a mixture of 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2®), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900®), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400 (registered trademark), or a combination thereof. 195. The composition of any one of paragraphs 138 to 194, wherein the weathering additive is a wet / dry adhesion promoter. 196. The composition of any one of paragraphs 138 to 195, wherein the weathering additive is present in a range of about 0.5% by weight to about 5% by weight, or about 1% by weight to about 5% by weight. 197. The composition according to any one of paragraphs 138 to 196, further comprising a curing catalyst. 198. The composition of any one of paragraphs 138 to 197, wherein the curing catalyst comprises 2,4,6-tris[(dimethylamino)methyl]phenol. 199. The composition according to any one of paragraphs 138 to 198, further comprising a hardener composition, the hardener composition comprising a hardener and optionally a diluent, the hardener being reactive in curing the composition to form a coating having resistance to an organic solvent buffing treatment of at least 50 passes, or 50 to 80 passes, as measured according to ASTM D1640. 200. The composition of any one of paragraphs 138 to 199, wherein the hardener comprises a silamine, an amine hardener, an amide hardener, or a combination thereof. 201. The composition of any one of paragraphs 138 to 200, wherein the hardener comprises a silamine hardener. 202. The composition of any one of paragraphs 138 to 201, wherein the silamine hardener comprises aminopropyltriethoxysilane, triaminofunctionalpropyltrimethoxysilane, or a combination thereof. 203. The composition of any one of paragraphs 138 to 202, wherein the curing agent is present in an amount to provide an epoxy group / NH ratio of about 0.9 to about 1.1, or about 1. 204. The composition of any one of paragraphs 138 to 203, wherein the hardener is present in a range of about 70% to about 100% by weight, or about 70% to about 90% by weight of the hardener composition. 205. The composition of any one of paragraphs 138 to 204, wherein the diluent comprises a non-reactive diluent. 206. The composition of any one of paragraphs 138 to 205, wherein the diluent comprises xylene, benzyl alcohol, methyl ethyl ketone, methyl acetate, an ether, an aromatic solvent, or a combination thereof. 207. The composition according to any one of paragraphs 138 to 205, wherein the diluent is present in the range of about 1 to about 20% by weight, or about 1 to about 30% by weight, of the hardener composition. 208. The composition of any one of paragraphs 138 to 206, wherein the hardener composition further comprises a curing catalyst. 209. The composition of any one of paragraphs 138 to 207, wherein the curing catalyst comprises 2,4,6-tris[(dimethylamino)methyl]phenol. 210. A coating comprising a reaction product of the coating composition according to any one of items 138 to 198 and a curing agent. 211. A coating comprising a reaction product of the coating composition according to any one of items 138 to 198 and the curing agent composition according to items 199 to 209. 212. The coating of any one of paragraphs 210-211, further comprising a primer coating, the primer coating comprising a reaction product of the primer coating composition and a curing agent. 213. The coating according to any one of paragraphs 210 to 212, wherein the primer coating composition comprises an epoxy resin or a urethane resin. 214. The coating according to any one of paragraphs 210 to 213, wherein the primer coating composition comprises an epoxy resin. 215. The coating according to any one of paragraphs 210 to 214, wherein the primer coating composition comprises at least 10% by weight of an epoxy resin. 216. The coating of any one of paragraphs 210 to 215, wherein the primer coating composition comprises an adhesion promoter comprising a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof. 217. The coating according to any one of paragraphs 210 to 216, wherein the primer coating composition comprises a filler for producing micro-roughness in the dried primer and for inducing gas-liquid barrier properties. 218. The coating of any one of paragraphs 210 to 217, wherein the filler comprises magnesium silicate (talc), wollastonite, barium sulfate, fumed silica, or a combination thereof, in an amount of 30% by weight or more, based on the total weight of the formulation. 219. A coating according to any one of paragraphs 210 to 218, having a flexural strength of at least 10 mm as measured in a cylindrical bending test. 220. A coating according to any one of paragraphs 210 to 219, having a flexural strength of at least 8 mm, or at least 6 mm, as measured in a cylindrical bend test. 221. The coating of any one of paragraphs 210-220, having a substrate adhesion of at least 3 MPa as measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa as measured according to ASTM D4541, or a combination thereof. 222. The coating of any one of paragraphs 210 to 221, having a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, or about 3 MPa to about 7 MPa, or about 5 MPa to about 7 MPa, as measured according to ASTM D4541, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, or about 3 MPa to about 7 MPa, or about 5 MPa to about 7 MPa, as measured according to ASTM D4541, or a combination thereof. 223. The coating of any one of paragraphs 210 to 222, having a dry adhesion to a metal substrate of at least 3 MPa, a wet adhesion to a metal substrate of at least 4 MPa, or a combination thereof. 224. The coating according to any one of paragraphs 210 to 223, having a dry adhesion of about 3 to about 15 MPa, or about 3 to about 10 MPa, or about 3 to about 5 MPa, a wet adhesion of about 4 to about 15 MPa, or about 4 to about 10 MPa, or about 5 to about 7 MPa, or a combination thereof. 225. The coating of any one of paragraphs 210 to 224, having a hardness of at least 5H as measured according to ASTM D3363. 226. The coating of any one of paragraphs 210 to 225, having a hardness of about 6H to about 8H, or about 8H. 227. Use of the coating composition according to any one of paragraphs 210 to 226 for forming a coating on a substrate. 228. The use according to paragraph 227, wherein the substrate is the surface of a marine vessel, such as a boat or ship, or the surface of a marine device, such as a sensor or a propeller. 229. The use according to any one of paragraphs 227 to 228, wherein the substrate is the surface of a propeller. 230. Use of a coating comprising a reaction product of a coating composition according to any one of paragraphs 138 to 198 and a curing agent to reduce cavitation. 231. Use of a coating comprising a reaction product of a coating composition according to any one of paragraphs 138 to 198 and a curing agent composition according to paragraphs 199 to 209 for reducing cavitation.
[0250] In order to better understand the invention described herein, the following examples are presented. It should be understood that these examples are for illustrative purposes only, and therefore should not be construed as limiting the scope of the invention in any way. EXAMPLES
[0251] Example 1: Coating composition, reducing noise emissions and / or increasing hardness 1.1 Materials used in the coating compositions prepared and tested [Table 1-1] [Table 1-2] 1.2 Coating Compositions - Formulations Prepared and Tested [Table 2] [Table 3]
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
Table 16
Table 17
Table 18
Table 19
Table 20
Claims
1. A coating composition comprising: a solvent-based monomer; a diluent; an adhesion promoter in an amount sufficient to provide a coating formed from said composition having a substrate adhesion of at least 3 MPa when measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa when measured according to ASTM D4541, or a recoat adhesion window of at least 4 hours when measured according to ASTM D3359; a rheology modifier in an amount sufficient to provide a coating formed from said composition having anti-settling, anti-sagging or surface leveling properties; a ceramic performance additive in an amount sufficient to provide a coating formed from said composition having a reduced noise emission of about 2 dB to about 10 dB per about 100 μm of coating thickness at frequencies from about 10 Hz to about 10 kHz when measured on a 3 mm thick cold rolled steel sheet coated with a coating without ceramic performance additives, or having a hardness of at least 5H when measured according to ASTM D3363; and a coating composition comprising the same.
2. The composition according to claim 1, wherein said solvent-based monomer comprises: an allyl-functional monomer, an amino-functional monomer, a maleimide-functional monomer, a cyanate ester-functional monomer, an epoxy-functional monomer, a furan-functional monomer, a vinyl ester-functional monomer, or a combination thereof; a solvent-based prepolymer, such as an allyl-functional prepolymer, an amino-functional prepolymer, a polyester prepolymer, a bismaleimide prepolymer, a cyanate ester-functional prepolymer, an epoxy-functional prepolymer, a furan-functional prepolymer, a phenolic prepolymer, a polyurea prepolymer, a polyurethane prepolymer, a silicone prepolymer, or a vinyl ester-functional prepolymer; and / or Epoxy-functional monomers, where the epoxy-functional monomers are bisphenol diglycidyl ether, epoxy-functional monomers modified with alicyclic polyglycidyl ethers, epoxy-functional monomers modified with aliphatic glycidyl ethers, epoxy-functional epoxysiloxane monomers, reaction products of epichlorohydrin with one or more of hydroxyl-functional aromatic compounds, alcohols, thiols, acids, acid anhydrides, alicyclic compounds, aliphatic compounds, polyfunctional amines, and amine-functional aromatic compounds, reaction products of the oxidation of unsaturated alicyclic compounds, or combinations thereof.
3. The epoxy-functional epoxysiloxane monomer is an epoxide main chain containing a siloxane side chain or a polysiloxane side chain, where optionally at least one of the siloxane side chain or the polysiloxane side chain is a crosslinked silicone resin; reaction products of isocyanate oligomers and / or polyurethane oligomers, silane oligomers, and epoxy oligomers; epoxy-functional epoxysiloxane prepolymers; 3-ethylcyclohexyl epoxy copolymer modified with dimethylsiloxane side chains, epoxy bisphenol A (2,2-bis(4'-glycidyloxyphenyl)propane) modified with polydimethylsiloxane side chains, siloxane-modified hybrid epoxy resins, silicone epoxide resins, epoxy-functional epoxide main chains functionalized with crosslinked silicone resins containing terminal alkoxy groups, or combinations thereof; and / or Silikopon® ED, Silikopon® EF, EPOSIL Resin 5550® or combinations thereof; The composition according to claim 2, comprising
4. The solvent-based monomer is a low-viscosity solvent-based monomer, The low-viscosity solvent-based monomer includes an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 350 to about 550 cps, an epoxy-functional monomer modified with an alicyclic polyglycidyl ether having a viscosity in the range of about 400 to about 1000 cps, an epoxy-functional monomer modified with an aliphatic glycidyl ether having a viscosity in the range of about 800 to about 1000 cps, or a combination thereof, and / or The low-viscosity solvent-based monomer includes DLVE®-52 (an ultra-low viscosity epoxy resin modified with an alicyclic polyglycidyl ether epoxy resin), DLVE®-18 (a low-viscosity epoxy resin modified with an alicyclic polyglycidyl ether epoxy resin), D.E.R.® 353 (a C12-C14 aliphatic glycidyl ether-modified bisphenol A / F epoxy resin), or a combination thereof, The composition according to claim 1.
5. The mixture of the solvent-based monomer and the diluent has a viscosity in the range of about 200 to about 3500 cps, or about 300 to about 3500 cps, The solvent-based monomer is present in the range of about 5 wt% to about 35 wt%, or about 5 wt% to about 30 wt%, or about 10 wt% to about 30 wt%, or about 15 wt% to about 20 wt% based on the weight % of part A, or in the range of about 5 wt% to about 25 wt%, or about 5 wt% to about 20 wt%, or about 10 wt% to about 20 wt%, or about 15 wt% to about 20 wt% based on the total weight %, and / or The diluent contains about 10 wt% of volatile organic compounds, or 10 wt% or less of volatile organic compounds, The composition according to claim 1.
6. The composition according to claim 1, wherein the diluent includes a reactive diluent, a non-reactive diluent, or a combination thereof that is reactive in the polymerization of the solvent-based monomer.
7. The reactive diluent includes poly[(phenyl glycidyl ether)-co-formaldehyde], alkyl (C12-C14) glycidyl ether, phenyl glycidyl ether, alkenyl-substituted phenyl glycidyl ether, butyl glycidyl ether, 2-ethylhexyl glycidyl ether, o-cresol glycidyl ether, alicyclic glycidyl ether, 1,2-epoxy-3-phenoxypropane, epoxy-functional polydimethylsiloxane, silicone amine, or a combination thereof, The non-reactive diluent includes xylene, cyclohexane, toluene, methyl acetate, methyl ethyl ketone, tert-butyl acetate, nonylphenol, cyclohexanedimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol, propylene glycol, phenol, methylstyrenated phenol, styrenated phenol, C12-C37 ether, low-viscosity hydrocarbon resin, aryl polyoxyethylene ether, or a combination thereof, and / or The non-reactive diluent includes benzyl alcohol, xylene, methyl acetate, ether, aromatic solvent, or a combination thereof, Optionally, The reactive diluent is present in the range of about 1 wt% to about 15 wt%, or about 1 wt% to about 10 wt%, or about 1 wt% to about 5 wt% based on the wt% or total wt% of part A, The non-reactive diluent is present in the range of about 1 wt% to about 20 wt%, or about 1 wt% to about 10 wt%, or about 5 wt% to about 20 wt% based on the wt% of part A, or in the range of about 5 wt% to about 25 wt%, or about 5 wt% to about 20 wt%, or about 10 wt% to about 20 wt% based on the total wt%, The composition according to claim 6.
8. The adhesion promoter is A silane accelerator that is optionally reactive in the polymerization of solvent-based monomers; a dry adhesion promoter that is optionally reactive in the polymerization of solvent-based monomers, reactive with a substrate, and / or reactive with a metal oxide; a wet adhesion promoter that is optionally reactive in the polymerization of solvent-based monomers, reactive with a substrate, and / or reactive with a metal oxide; a dry / wet adhesion promoter that is optionally reactive, optionally reactive in the polymerization of solvent-based monomers, reactive with a substrate, and / or reactive with a metal oxide; or a combination thereof; Alkoxylated silanes, such as epoxy-functional alkoxylated silanes, amino-functional alkoxylated silanes, or combinations thereof; modified polyesters, such as modified polyesters having a sufficient hydroxyl value of about 30 mg to about 100 mg KOH / g, polyacrylic acid, modified polyester oligomers, polyacrylates, metal-doped phosphosilicates, benzotriazoles, polymers or prepolymers containing mercaptans, or combinations thereof; and / or 3-(2,3-Epoxypropoxy)propyltrimethoxysilane; glycidoxypropyltrimethoxysilane; aminopropyltriethoxysilane; 3-aminopropyltriethoxysilane; secondary aminobissilane; modified polyesters, such as Tego Addbond LTW-B (registered trademark), Tego Addbond 2220 ND (registered trademark); strontium silicate, such as HALOX (registered trademark) SW-111; zinc calcium strontium aluminum orthophosphate silicate hydrate, such as HEUCOPHOS (registered trademark) ZCP-Plus; zinc silicate, such as InvocoCor CI-3315 (Invotec); alkyl-substituted hydroxylamine-substituted benzotriazole, such as CCI-01 copper adhesion promoter; polymers or prepolymers containing mercaptans, such as CAPTURE (registered trademark) 3-800, CAPTURE (registered trademark) 40 SEC HV; or combinations thereof; comprising, and optionally, the adhesion promoter is present in an amount of about 1 wt% to about 10 wt%, or about 2 wt% to about 10 wt%, or about 2 wt% to about 8 wt% based on the weight % of part A, or in the range of about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1 wt%, or about 1 wt% to about 5 wt% based on the total weight %, The composition according to claim 1.
9. providing a coating formed from the composition having a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, or a recoat adhesion window of about 4 hours to about 72 hours, or combinations thereof, when measured according to ASTM D4541, the composition according to claim 1.
10. The composition according to claim 1, wherein the ceramic performance additive comprises hollow ceramics and non-hollow ceramics.
11. The hollow ceramic is hollow ceramic spheres having a particle size of about 10 μm to about 40 μm, about 20 μm to about 40 μm, or about 25 μm to about 35 μm, or about 10 μm to about 15 μm, or about 12 μm; present in the range of about 30 wt% to about 70 wt%, or about 35 wt% to about 65 wt%, or about 30 wt% to about 50 wt% based on the weight % of part A, or in the range of about 15 wt% to about 50 wt%, or about 20 wt% to about 50 wt%, or about 20 wt% to about 45 wt%, or about 15 wt% to about 40 wt% based on the weight % or total weight % of part A, hollow ceramic spheres having a particle size of about 20 μm to about 40 μm, or about 25 μm to about 35 μm. Based on Part A, in the range of about 5 wt% to about 70 wt%, about 15 wt% to about 70 wt%, about 25 wt% to about 70 wt%, about 35 wt% to about 70 wt%, about 40 wt% to about 70 wt%, or about 5 wt% to about 20 wt%, or about 10 wt% to about 20 wt%, or about 10 wt% to about 18 wt%, or about 10 wt% to about 15 wt%, or, based on the total wt%, in the range of about 20 wt% to about 50 wt%, or about 20 wt% to about 45 wt%, or about 15 wt% to about 40 wt%, hollow ceramic spheres having a particle size of about 10 μm to about 15 μm, or about 12 μm; and / or Hollow ceramic spheres including Zeospheres (registered trademark) G 600 hollow ceramic spheres, W410 (registered trademark) hollow ceramic spheres, W610 (registered trademark) hollow ceramic spheres, Zeospheres (registered trademark) N-200PC hollow ceramic spheres, W210 (registered trademark) hollow ceramic spheres, W410 (registered trademark) hollow ceramic spheres, W610 (registered trademark) hollow ceramic spheres, or combinations thereof, The composition according to claim 10, comprising
12. The non-hollow ceramic is Non-hollow ceramic particles having a particle size of about 0.1 μm to about 5 μm, about 0.5 μm to about 5 μm, or about 1 μm to about 5 μm, or about 2 μm to about 5 μm; Based on the wt% of Part A, in the range of about 10 wt% to about 50 wt%, or about 10 wt% to about 45 wt%, or about 15 wt% to about 40 wt%, or, based on the total wt%, in the range of about 5 wt% to about 40 wt%, or about 10 wt% to about 35 wt%, or about 20 wt% to about 35 wt%, or about 10 wt% to about 20 wt%, non-hollow ceramic particles present; and / or Non-hollow ceramic particles including titanium oxide, brown aluminum (III) oxide, fused aluminum (III) oxide, titanium alloy, or combinations thereof, The composition according to claim 10, comprising
13. A composition according to claim 1, wherein a sufficient amount of said ceramic performance additive provides a coating formed from said composition having a reduced noise emission of about 3 dB to about 9 dB, or about 5 dB to about 7 dB, per about 100 μm of coating thickness, or a hardness of about 6 H to about 8 H, or about 8 H. **Claim 14** The composition according to claim 1, wherein said rheology modifier comprises an anti-settling rheology modifier, an anti-sagging rheology modifier, or a combination thereof. **Claim 15** The rheology modifier comprises aluminum phyllosilicate clay; an organically modified derivative of aluminum phyllosilicate clay; organically modified bentonite clay; organically modified montmorillonite clay, such as Claytone-HY® or Claytone-APA®; an organically modified castor oil derivative wax, such as Thixatrol ST®; a micronized organically modified polyamide wax derivative, such as Crayvallac Super®; fumed silica, fumed silica surface-modified with silane, fumed silica surface-modified with dimethyldichlorosilane, such as Cab-O-Sil TS-610®; micronized barium sulfate, such as VB Techno®; microcrystalline magnesium silicate, such as Talc Silverline 202® or Mistron 002®; a polyether siloxane copolymer, such as TEGO® Glide 410® (Evonik); or a combination thereof, The anti-settling rheology modifier comprises fumed silica, fumed silica surface-modified with silane, fumed silica surface-modified with dimethyldichlorosilane, aluminum phyllosilicate clay, an organically modified derivative of aluminum phyllosilicate clay, organically modified bentonite clay, organically modified montmorillonite clay, or a combination thereof, and / or The anti-sagging rheology modifier comprises a micronized organically modified polyamide wax derivative, an organically modified castor oil derivative wax, or a combination thereof, Optionally, The rheology modifier is present in the range of about 1 wt% to about 5 wt%, or about 1 wt% to about 3 wt%, or about 1 wt% to about 1.5 wt% based on the weight% of part A, or in the range of about 0.3 wt% to about 5 wt%, or about 0.3 wt% to about 3 wt%, or about 0.3 wt% to about 1.5 wt% based on the total weight%. The anti-drip rheology modifier or the anti-settling rheology modifier is present in the range of about 0.1 wt% to about 5 wt%, or about 0.3 wt% to about 3 wt%, or about 0.3 wt% to about 1.5 wt% based on the total weight%. The composition according to claim 14.
16. The composition according to claim 1, further comprising a dispersant.
17. The dispersant is a polymer dispersant, for example, a polymer non-ionic dispersant, a polymer ionic dispersant, a polymer pigment dispersant, or a combination thereof; and / or ADDITOL VXW 6208 (Registered Trademark) (polymeric nonionic dispersant), K-SPERSE A504 (Registered Trademark) (polymeric nonionic dispersant), Disperbyk 140 (Registered Trademark) (polymeric ionic dispersant, alkylammonium salt of acidic polymer), MULTIWET EF-LQ-AP (Registered Trademark) (polymeric nonionic dispersant), HYPERMER KD6-LQ-MV (Registered Trademark) (polymeric nonionic dispersant blend), ECO NatraSense 125 MBAL-LQ-AP (Registered Trademark) (nonionic alcohol ethoxylate dispersant), BRJ-03-LQ-AP (Registered Trademark) (nonionic alkyl polyglycol ether dispersant), SP BRJ 02 MBAL LQ-AP (Registered Trademark) (nonionic alkyl polyglycol ether dispersant), ANTI-TERRA-204 (Registered Trademark) (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670 (Registered Trademark) (polymeric nonionic dispersant), TEGO Dispers 1010 (Registered Trademark) (polymeric nonionic dispersant), TEGO (Registered Trademark) Glide 410 (Registered Trademark) (polyether siloxane copolymer), or a combination thereof; comprising optionally, the dispersant is present in the range of about 0.1 wt% to about 2 wt%, or about 0.1 wt% to about 1.5 wt%, or about 0.1 wt% to about 1 wt% based on the weight% of part A, or in the range of about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 4 wt%, or about 0.1 wt% to about 3 wt%, or about 0.1 wt% to about 2 wt%, or about 0.1 wt% to about 1 wt% based on the total weight%; The composition according to claim 16.
18. an antiwear agent; and / or an antiwear agent comprising graphite oxide, multilayer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or a combination thereof, further comprising optionally, The anti-wear agent is present in the range of about 0.01 wt% to about 5 wt%, 0.05 wt% to about 5 wt%, 0.5 wt% to about 5 wt%, or about 0.5 wt% to about 2 wt% based on the wt% or total wt% of part A. The composition according to claim 1.
19. Further comprising a hydrophobicity adjusting additive, wherein the hydrophobicity adjusting additive comprises an epoxy-functional silane, an epoxy-functional polydialkylsiloxane, or a combination thereof, the composition according to claim 1.
20. The composition according to claim 19, wherein the hydrophobicity adjusting additive comprises an epoxy-functional polydialkylsiloxane and / or glycidoxypropyltrimethoxysilane.
21. The composition according to claim 1, further comprising an antifoaming agent.
22. The antifoaming agent is a polymer antifoaming agent; a silicone-based oligomer antifoaming agent, where optionally, the silicone-based oligomer antifoaming agent is a polysiloxane oligomer; and / or BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airx 900, or a combination thereof; and The antifoaming agent is optionally in the range of about 1 wt% to about 5 wt%, or about 1 wt% to about 3 wt%, or about 1 wt% to about 1.5 wt% based on the wt% of part A, or in the range of about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1 wt%, or about 1 wt% to about 5 wt% based on the total wt%. The composition according to claim 21.
23. The composition according to claim 1, further comprising a weather resistance additive.
24. The weather resistance additive is a wetting / drying adhesion promoter; and / or The weather resistance additive includes 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9 branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2 (registered trademark)), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900 (registered trademark)), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400 (registered trademark)), or a combination thereof, Optionally, the weather resistance additive is present in the range of about 0.5 wt% to about 5 wt%, or about 1 wt% to about 5 wt%. The composition according to claim 23.
25. The composition according to claim 1, further comprising a curing catalyst, and optionally, the curing catalyst includes 2,4,6-tris[(dimethylamino)methyl]phenol.
26. The composition according to claim 1, containing about 80 wt% to about 90 wt% solids.
27. The composition according to claim 1, further comprising a curing agent composition, the curing agent composition includes a curing agent and optionally a diluent, the curing agent is reactive when curing the composition, and forms a coating having resistance to abrasive treatment with an organic solvent of at least 50 passes, or 50 - 80 passes when measured according to ASTM D1640.
28. The hardener includes an amine hardener, an amide hardener, or a combination thereof, such as phenalkamine, amine-modified phenalkamine, phenalamide, amine-modified phenalamide, polyamideamine, organically modified polyamideamine, or a combination thereof; or a silamine hardener, such as aminopropyltriethoxysilane, triaminofunctional propyltrimethoxysilane; or a combination thereof, and optionally exists in the range of about 40 wt% to about 100 wt%, or 40 wt% to about 90 wt%, or about 70 wt% to about 100 wt%, or about 70 wt% to about 90 wt% of the hardener composition, and / or The diluent includes a non-reactive diluent, such as xylene, benzyl alcohol, methyl ethyl ketone, methyl acetate, ether, aromatic solvent, or a combination thereof, and optionally exists in the range of about 1 to 30 wt% of the hardener composition, and optionally, the xylene exists in the range of about 1 wt% to about 5 wt%, and methyl acetate exists in the range of about 10 wt% to about 25 wt%. The composition according to claim 27.
29. A reaction product of a coating composition according to any one of claims 1 to 26 and a hardener, or a coating comprising a reaction product of a coating composition according to any one of claims 1 to 26 and a hardener according to claim 27 or 28.
30. The coating according to claim 29, wherein The bending strength is at least 10 mm when measured by a cylindrical bending test; The bending strength is at least 8 mm, or at least 6 mm when measured by a cylindrical bending test; The substrate adhesion is at least 3 MPa when measured according to ASTM D4541, the overcoat adhesion is at least 3 MPa when measured according to ASTM D4541, or the recoat adhesion window is at least 4 hours when measured according to ASTM D3359, or a combination thereof; A substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa when measured according to ASTM D4541, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa when measured according to ASTM D4541, or a recoat adhesion window of about 4 hours to about 72 hours when measured according to ASTM D3359, or a combination thereof; Compared with a 3 mm thick cold-rolled steel sheet coated with a coating without the ceramic performance additive, when measured on a 3 mm thick cold-rolled steel sheet, at a frequency of about 10 Hz to about 10 kHz, a reduced noise radiation of about 2 dB to about 10 dB per about 100 μm of coating thickness, or a hardness of at least 5 H when measured according to ASTM D3363; and / or A reduced noise radiation of about 3 dB to about 9 dB, or about 5 dB to about 7 dB per about 100 μm of coating thickness, or a hardness of about 6 H to about 8 H, or about 8 H; The coating according to claim 29, having
31. A coating composition comprising A solvent-based epoxy resin, A diluent, An adhesion promoter, A sedimentation-preventing rheology modifier, A sag-preventing rheology modifier, A ceramic performance additive containing hollow ceramic spheres, And a coating composition containing
32. The epoxy resin includes bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin, alicyclic polyglycidyl ether-modified epoxy resin, alicyclic polyglycidyl ether resin having a viscosity in the range of about 350 to about 550 cps, alicyclic polyglycidyl ether-modified resin having a viscosity in the range of about 400 to about 1000 cps, aliphatic glycidyl ether-modified epoxy resin having a viscosity in the range of about 800 to about 1000 cps, or a combination thereof, Optionally, The epoxy resin is present in an amount of about 5 to about 30 wt%, or about 5 to about 20 wt%, or about 15 to about 20 wt%, or about 10 wt% to about 20 wt% based on the wt% of part A. The composition according to claim 31.
33. The diluent includes a reactive diluent that is reactive in epoxy polymerization, a non-reactive diluent, or a combination thereof. Optionally, The reactive diluent includes butyl glycidyl ether, C12-C14 aliphatic glycidyl ether, phenyl glycidyl ether, alkenyl-substituted phenyl glycidyl ether, 2-ethylhexyl glycidyl ether, o-cresol glycidyl ether, alicyclic glycidyl ether, 1,2-epoxy-3-phenoxypropane, epoxy-functional polydimethylsiloxane, or a combination thereof. The non-reactive diluent includes xylene, cyclohexane, toluene, methyl acetate, methyl ethyl ketone, tert-butyl acetate, nonylphenol, cyclohexanedimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol, propylene glycol, phenol, or a combination thereof, and / or The non-reactive diluent includes benzyl alcohol, xylene, methyl ethyl ketone, methyl acetate, ether, aromatic solvent, or a combination thereof. The composition according to claim 31.
34. The reactive diluent is in the range of about 1 wt% to about 15 wt%, or about 1 wt% to about 10 wt%, or about 5 wt% to about 10 wt%, or about 1 wt% to about 5 wt% based on the wt% of part A, or in the range of about 1 wt% to about 10 wt%, or about 2 wt% to about 8 wt% based on the total wt%, and / or The non-reactive diluent is in the range of about 1 wt% to about 20 wt%, or about 1 wt% to about 10 wt%, or about 5 wt% to about 20 wt% based on the wt% of part A or the total wt%. The composition according to claim 33.
35. The adhesion promoter is An alkoxylated silane that is optionally reactive in epoxy polymerization, a hydroxyphenyl-benzotriazole, a hydroxyphenyl-triazine, or a combination thereof; An epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, a hydroxyphenylbenzotriazole, a hydroxyphenyltriazine, or a combination thereof; 3-(2,3-Epoxypropoxy)propyltrimethoxysilane, glycidoxypropyltrimethoxysilane, aminopropyltriethoxysilane, 3-aminopropyltriethoxysilane, secondary aminobissilane, 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9 branched and linear alkyl ester and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2 (registered trademark)), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900 (registered trademark)), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400 (registered trademark)), or a combination thereof, comprising optionally The adhesion promoter is present in the range of about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1 wt%, or about 1 wt% to about 5 wt% based on the wt% or total wt% of part A. The composition according to claim 31.
36. The anti-settling rheology modifier is Silica, clay, or a combination thereof; and / or fumed silica, fumed silica surface-modified with silane, fumed silica surface-modified with dimethyldichlorosilane, aluminum phyllosilicate clay, an organically modified derivative of aluminum phyllosilicate clay, an organically modified bentonite clay, an organically modified montmorillonite clay, or a combination thereof; comprising optionally the anti-settling rheology modifier is present in the range of about 0.1 wt% to about 5 wt%, or about 0.3 wt% to about 3 wt%, or about 0.3 wt% to about 2 wt% based on the weight % of part A, or in the range of about 0.1 wt% to about 2 wt%, or about 0.2 wt% to about 1.5 wt%, or about 0.3 wt% to about 1.3 wt% based on the total weight %; The composition according to claim 31.
37. The anti-sagging rheology modifier is wax, micronized wax, or a combination thereof; polyamide wax, micronized polyamide wax, micronized organically modified polyamide wax, micronized organically modified polyamide wax derivative, castor oil wax, organically modified castor oil derivative wax, or a combination thereof; and / or polyamide wax, micronized polyamide wax, micronized organically modified polyamide wax, micronized organically modified polyamide wax derivative, or a combination thereof; comprising optionally the anti-sagging rheology modifier is present in the range of about 0.1 wt% to about 1.5 wt%, or about 0.1 wt% to about 1 wt%, or about 0.1 wt% to about 0.5 wt% based on the weight % of part A or the total weight %; The composition according to claim 31.
38. the ceramic performance additive comprises hollow ceramic spheres, and the hollow ceramic spheres are having a particle size of from about 20 μm to about 40 μm, or from about 25 μm to about 35 μm, present in the range of from about 20 wt% to about 40 wt%, or from about 25 wt% to about 35 wt%, based on the wt% or total wt% of part A, and / or The composition according to claim 31, comprising Zeospheres (registered trademark) G 600 hollow ceramic spheres, W410 (registered trademark) hollow ceramic spheres, W610 (registered trademark) hollow ceramic spheres, or a combination thereof.
39. The composition according to claim 31, further comprising a dispersant, Optionally, the dispersant comprises a polymer dispersant, the dispersant comprises a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof, the dispersant is ADDITOL VXW 6208 (registered trademark) (polymeric nonionic dispersant), K-SPERSE A504 (polymeric nonionic graphene dispersant), MULTIWET EF-LQ-AP (registered trademark) (polymeric nonionic dispersant), HYPERMER KD6-LQ-MV (registered trademark) (polymeric nonionic dispersant blend), BRJ-03-LQ-AP (registered trademark) (nonionic alkyl polyglycol ether dispersant), SP BRJ 02 MBAL LQ-AP (registered trademark) (nonionic alkyl polyglycol ether dispersant), ANTI-TERRA-204 (registered trademark) (polymeric ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670 (registered trademark) (polymeric nonionic dispersant), TEGO Dispers 1010 (registered trademark) (polymeric nonionic dispersant), TEGO (registered trademark) Glide 410 (registered trademark) (polyether siloxane copolymer), or a combination thereof, and / or the dispersant is present in the range of from about 0.1 wt% to about 1.5 wt%, or from about 0.1 wt% to about 1 wt%, or from about 0.1 wt% to about 0.5 wt%, based on the wt% of part A or the total wt%, The composition according to claim 31.
40. The composition according to claim 31, further comprising an anti-wear agent, optionally, the anti-wear agent comprises graphite oxide, graphene, multi-layer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or a combination thereof, and / or the anti-wear agent is present in the range of about 0.01 wt% to about 1 wt%, or about 0.05 wt% to about 0.5 wt%, or about 0.05 wt% to about 0.8 wt% based on the weight % or total weight % of part A, The composition according to claim 31.
41. The composition according to claim 31, further comprising an anti-foaming agent, optionally, the anti-foaming agent comprises a polymer anti-foaming agent, the anti-foaming agent comprises a silicone-based oligomer anti-foaming agent, the anti-foaming agent comprises BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airex 900, or a combination thereof, and / or the anti-foaming agent is optionally in the range of about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1.5 wt%, or about 0.3 wt% to about 1.2 wt%, or about 1 wt% to about 5 wt% based on the weight % or total weight % of part A, The composition according to claim 31.
42. The composition according to claim 31, further comprising a curing catalyst, The composition according to claim 31, wherein the curing catalyst comprises 2,4,6-tris[(dimethylamino)methyl]phenol.
43. The composition according to claim 31, further comprising a curing agent composition, the curing agent composition comprising a curing agent and optionally a diluent, the curing agent being reactive when curing the composition and forming a coating having resistance to abrasive treatment with an organic solvent of at least 50 passes, or 50 to 80 passes as measured according to ASTM D1640, optionally, The hardener includes an amine hardener, an amide hardener, or a combination thereof, The hardener includes a phenalkamine, an amine-modified phenalkamine, a phenalkamide, an amine-modified phenalkamide, a polyamideamine, an organically modified polyamideamine, or a combination thereof, The hardener is present in an amount that provides an epoxy group / NH ratio of from about 1.2 to about 1.4, The hardener is present in the range of about 70 wt% to about 100 wt%, or about 70 wt% to about 90 wt% of the hardener composition, The diluent includes xylene, benzyl alcohol, methyl ethyl ketone, methyl acetate, ether, an aromatic solvent, or a combination thereof, and / or The diluent is present in the range of about 1 to 30 wt%, or about 5 to 25 wt%, or about 10 to 25 wt%, or about 1 to 5 wt% of the hardener composition, The composition according to claim 31.
44. A coating comprising a reaction product of a coating composition according to any one of claims 31 to 42 and a hardener, and / or a reaction product of a coating composition according to any one of claims 31 to 42 and a hardener composition according to claim 43, Optionally, the coating further comprises a primer coating and / or a topcoat coating.
45. A coating according to claim 44, A bending strength of at least 10 mm when measured by a cylindrical bending test; A bending strength of at least 8 mm, or at least 6 mm when measured by a cylindrical bending test; A substrate adhesion of at least 3 MPa when measured according to ASTM D4541, an overcoat adhesion of at least 3 MPa when measured according to ASTM D4541, or a recoat adhesion window of at least 4 hours when measured according to ASTM D3359, or a combination thereof; a substrate adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, an overcoat adhesion of about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, as measured according to ASTM D4541, or a recoat adhesion window of about 4 hours to about 72 hours, as measured according to ASTM D3359, or a combination thereof; and / or a reduced noise emission of about 2 dB to about 10 dB per about 100 μm of coating thickness at frequencies from about 10 Hz to about 10 kHz, as measured on a 3 mm thick cold rolled steel sheet compared to a 3 mm thick cold rolled steel sheet coated with a coating that does not contain the ceramic performance additive; and / or reduced noise emissions of about 3 dB to about 9 dB, about 5 dB to about 9 dB, or about 5 dB to about 7 dB per about 100 μm of coating thickness; 45. The coating of claim 44, having the following formula:
46. 45. Use of the coating composition of claim 44 to form a coating on a substrate, comprising: Optionally, the substrate is a surface of a marine vessel, such as a boat or ship, or a surface of a marine device, such as a sensor or a propeller; and / or The substrate is a surface of a hull of a marine vessel; Use of the coating composition according to claim 44.
47. Use of a reaction product of a coating composition according to any one of claims 31 to 42 and a hardener for reducing underwater radiated noise, or a coating comprising a reaction product of a coating composition according to any one of claims 31 to 42 and a hardener composition according to claim 43 for reducing underwater radiated noise.
48. A coating composition comprising: A solvent-based epoxy resin; A diluent; An adhesion promoter comprising a drying adhesion promoter, a wetting adhesion promoter, a drying / wetting adhesion promoter, or a combination thereof, a rheology modifier comprising a sedimentation prevention rheology modifier, a sag prevention rheology modifier, a surface leveling rheology modifier, or a combination thereof, a ceramic performance additive comprising hollow ceramic spheres, non-hollow ceramic particles, or a combination thereof, and a coating composition comprising the same.
49. The composition according to claim 48, wherein the epoxy resin comprises a hybrid epoxy siloxane resin, and optionally, the epoxy resin is present in an amount of about 30 to about 55 wt%, or about 40 to about 50 wt%, based on part A.
50. The composition according to claim 48, further comprising a hydrophobicity adjusting additive, wherein the hydrophobicity adjusting additive comprises an epoxy-functional silane, an epoxy-functional polydialkylsiloxane, or a combination thereof, optionally, the hydrophobicity adjusting additive comprises an epoxy-functional polydialkylsiloxane, the hydrophobicity adjusting additive comprises an epoxy-functional polydimethylsiloxane, the epoxy-functional silane comprises glycidoxypropyltrimethoxysilane, and the composition according to claim 48.
51. The diluent comprises a non-reactive diluent, optionally, the non-reactive diluent comprises xylene, cyclohexane, toluene, methyl acetate, methyl ethyl ketone, tert-butyl acetate, nonylphenol, cyclohexanedimethanol, n-butyl alcohol, benzyl alcohol, isopropyl alcohol, polyethylene glycol, propylene glycol, phenol, or a combination thereof, the non-reactive diluent comprises benzyl alcohol, xylene, methyl ethyl ketone, methyl acetate, ether, or an aromatic solvent, or a combination thereof, and / or The non-reactive diluent is present in the range of about 1 wt% to about 20 wt%, or about 1 wt% to about 10 wt%, or about 5 wt% to about 20 wt%, or about 5 wt% to about 15 wt% based on the wt% of part A, or in the range of about 1 wt% to about 25 wt%, or about 5 wt% to about 20 wt%, or about 5 wt% to about 15 wt% based on the total wt%. The composition according to claim 48.
52. The dry adhesion promoter, the dry / wet adhesion promoter, and / or the wet adhesion promoter is non-reactive, reactive in epoxy resin polymerization, reactive with the substrate, and / or reactive with metal oxides, or a combination thereof; a metal adhesion promoter; and / or a copper or aluminum adhesion promoter; and optionally, the adhesion promoter is present in the range of about 0.1 wt% to about 10 wt%, about 0.1 wt% to about 8 wt%, about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1 wt%, or about 1 wt% to about 5 wt%, or about 1 wt% to about 8 wt% based on the wt% of part A or the total wt%. The composition according to claim 48.
53. The dry adhesion promoter is non-reactive, reactive in epoxy resin polymerization, reactive with the substrate, and / or reactive with metal oxides, and contains an alkoxylated silane, and / or contains an epoxy-functional alkoxylated silane, an amino-functional alkoxylated silane, or a combination thereof, the wet adhesion promoter is reactive with the substrate, contains a metal-doped phosphosilicate, and / or contains strontium silicate, zinc silicate, zinc calcium strontium aluminum orthophosphate silicate hydrate, or a combination thereof, and / or the drying / wetting adhesion promoter is non-reactive, reactive with the substrate, and / or reactive with the metal oxide, and / or contains a modified polyester, a modified polyester oligomer, polyacrylic acid, polyacrylate, benzotriazole, a polymer or prepolymer containing mercaptan, or a combination thereof, and optionally, the modified polyester contains a modified polyester having a sufficient hydroxyl value of about 30 mg to about 100 mg KOH / g, and / or the benzotriazole contains an alkyl-substituted hydroxylamine-substituted benzotriazole, hydroxyphenylbenzotriazole, or a combination thereof, The composition according to claim 52.
54. the anti-settling rheology modifier is contains silica, clay, or a combination thereof, contains fumed silica, fumed silica surface-modified with silane, fumed silica surface-modified with dimethyldichlorosilane, or a combination thereof, and / or is present in the range of about 0.1 wt% to about 5 wt%, or about 0.3 wt% to about 3 wt%, or about 0.3 wt% to about 2 wt% based on the wt% or total wt% of part A, the anti-sagging rheology modifier is contains wax, derivatized wax, or a combination thereof, contains castor oil wax, organically modified castor oil derivative wax, polyamide wax, micronized polyamide wax, micronized organically modified polyamide wax, micronized organically modified polyamide wax derivative, or a combination thereof, and / or is present in the range of about 0.1 wt% to about 1.5 wt%, or about 0.1 wt% to about 1 wt%, or about 0.1 wt% to about 0.5 wt% based on the wt% or total wt% of part A, and / or the surface leveling rheology modifier is comprising a polyether siloxane copolymer and / or present in an amount of from about 0.1 wt% to about 1.5 wt%, or from about 0.1 wt% to about 1 wt%, or from about 0.1 wt% to about 0.5 wt%, based on the wt% or total wt% of part A, The composition according to claim 48.
55. wherein the hollow ceramic is a hollow ceramic sphere having a particle size of from about 10 μm to about 40 μm, from about 20 μm to about 40 μm, or from about 25 μm to about 35 μm, or from about 10 μm to about 15 μm, or about 12 μm; and / or hollow ceramic spheres present in an amount of from about 5 wt% to about 15 wt%, comprising and / or wherein the non-hollow ceramic particles have a particle size of from about 0.1 μm to about 5 μm, from about 0.5 μm to about 5 μm, or from about 1 μm to about 5 μm, or from about 2 μm to about 5 μm, are present in an amount of from about 5 wt% to about 40 wt%, or from about 10 wt% to about 35 wt%, or from about 20 wt% to about 35 wt%, or from about 10 wt% to about 20 wt%, based on the wt% of part A or the total wt%, and comprise titanium oxide, fumed silica, brown aluminum (III) oxide, fused aluminum (III) oxide, titanium alloy, or a combination thereof, and / or comprise titanium alloy, titanium carbonitride, titanium carbide, or a combination thereof, The composition according to claim 48.
56. The composition according to claim 48, further comprising - a dispersant where optionally the dispersant comprises a polymer dispersant the dispersant comprises a polymeric nonionic dispersant, a polymeric ionic dispersant, a polymeric pigment dispersant, or a combination thereof, The dispersant includes ADDITOL VXW 6208 (registered trademark) (polymer nonionic dispersant), K-SPERSE A504 (polymer nonionic graphene dispersant), MULTIWET EF-LQ-AP (registered trademark) (polymer nonionic dispersant), HYPERMER KD6-LQ-MV (registered trademark) (polymer nonionic dispersant blend), BRJ-03-Lam Q-AP (registered trademark) (nonionic alkyl polyglycol ether dispersant), SP BRJ 02 MBAL LQ-AP (registered trademark) (nonionic alkyl polyglycol ether dispersant), ANTI-TERRA-204 (registered trademark) (polymer ionic dispersant, polycarboxylate of polyamine amide), TEGO Dispers 670 (registered trademark) (polymer nonionic dispersant), TEGO Dispers 1010 (registered trademark) (polymer nonionic dispersant), TEGO (registered trademark) Glide 410 (registered trademark) (polyether siloxane copolymer), or a combination thereof, and / or The dispersant is present in the range of about 0.1 wt% to about 1.5 wt%, or about 0.1 wt% to about 1 wt%, or about 0.1 wt% to about 0.5 wt% based on the wt% or total wt% of part A; - Antiwear agent, Here, optionally, The antiwear agent includes graphite oxide, graphene, multi-layer graphene flakes, titanium dioxide, microcrystalline magnesium silicate, fumed silica, micronized barium sulfate, or a combination thereof, and / or The antiwear agent is present in the range of about 0.01 wt% to about 1 wt%, or about 0.05 wt% to about 0.5 wt%, or about 0.05 wt% to about 0.8 wt% based on the total wt%; - Antifoaming agent, Here, optionally, The antifoaming agent includes a polymer antifoaming agent, The antifoaming agent includes a silicone-based oligomer antifoaming agent, The defoaming agent includes BYK-066 N, BYK-1790, ADDITOL VXW 6210 N, TEGO Airx 900, or a combination thereof, and / or The defoaming agent is in the range of about 0.1 wt% to about 5 wt%, or about 0.1 wt% to about 1 wt%, or about 1 wt% to about 5 wt% based on the wt% or total wt% of part A; - Weather resistance additive, Here, optionally, The weather resistance additive includes hydroxyphenylbenzotriazole, hydroxyphenyltriazine, or a combination thereof, The weather resistance additive is 95% benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxy-, C7-9 branched and linear alkyl esters and 5% 1-methoxy-2-propyl acetate (Tinuvin 99-2 (registered trademark)), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (Tinuvin 900 (registered trademark)), 2-[4-[2-hydroxy-3-tridecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-didecyloxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (Tinuvin 400 (registered trademark)), or a combination thereof, The weather resistance additive is a wetting / drying adhesion promoter, and / or The weather resistance additive is present in the range of about 0.5 wt% to about 5 wt%, or about 1 wt% to about 5 wt%; and / or - Curing catalyst, Here, optionally, The curing catalyst includes 2,4,6-tris[(dimethylamino)methyl]phenol, The composition according to claim 48.
57. Further comprising a curing agent composition, said curing agent composition comprising a curing agent and optionally a diluent, said curing agent being reactive when curing said composition and having resistance to polishing treatment with an organic solvent of at least 50 passes, or 50 to 80 passes, as measured according to ASTM D1640, to form a coating, Optionally, said curing agent comprises silamine, amine curing agent, amide curing agent, or a combination thereof, said curing agent comprises a silamine curing agent, said silamine curing agent comprising aminopropyltriethoxysilane, triaminofunctional propyltrimethoxysilane, or a combination thereof, said curing agent is present in an amount providing an epoxy group / NH ratio of about 0.9 to about 1.1, or about 1, said curing agent is present in the range of about 70 wt% to about 100 wt%, or about 70 wt% to about 90 wt% of said curing agent composition, said diluent comprises a non-reactive diluent, said diluent comprises xylene, benzyl alcohol, methyl ethyl ketone, methyl acetate, ether, aromatic solvent, or a combination thereof, and / or said diluent is present in the range of about 1 to about 20 wt%, or about 1 to about 30 wt% of said curing agent composition, The composition according to claim 48.
58. The composition according to claim 48, wherein said curing agent composition further comprises a curing catalyst, and optionally, said curing catalyst comprises 2,4,6-tris[(dimethylamino)methyl]phenol.
59. A reaction product of a coating composition according to any one of claims 48 to 56 and a curing agent, and / or a coating comprising a reaction product of a coating composition according to any one of claims 48 to 56 and a curing agent composition according to claim 57 or 58. **Claim 60**: The coating according to claim 59, further comprising a primer coating, wherein the primer coating comprises a reaction product of a primer coating composition and a curing agent, the coating according to claim 59. **Claim 61** The primer coating composition comprises an epoxy resin or a urethane resin; at least 10% by weight of an epoxy resin; an adhesion promoter comprising a dry adhesion promoter, a wet adhesion promoter, a dry / wet adhesion promoter, or a combination thereof; and / or a filler for producing a fine roughness in the dry primer and inducing gas-liquid barrier properties, comprising optionally, the filler comprises magnesium silicate (talc), wollastonite, barium sulfate, fumed silica, or a combination thereof in an amount of 30% by weight or more based on the total weight of the formulation, the coating according to claim 59. **Claim 62**: The coating according to claim 59, wherein the bending strength is at least 10 mm when measured by a cylindrical bending test; the bending strength is at least 8 mm, or at least 6 mm when measured by a cylindrical bending test; the substrate adhesion is at least 3 MPa when measured according to ASTM D4541, the overcoat adhesion is at least 3 MPa when measured according to ASTM D4541, or a combination thereof; the substrate adhesion is about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, or about 3 MPa to about 7 MPa, or about 5 MPa to about 7 MPa when measured according to ASTM D4541, the overcoat adhesion is about 3 MPa to about 15 MPa, or about 3 MPa to about 10 MPa, or about 3 MPa to about 7 MPa, or about 5 MPa to about 7 MPa when measured according to ASTM D4541, or a combination thereof; A dry adhesive strength to a metal substrate of at least 3 MPa, a wet adhesive strength to a metal substrate of at least 4 MPa, or a combination thereof; A dry adhesive strength of about 3 to about 15 MPa, or about 3 to about 10 MPa, or about 3 to about 5 MPa, a wet adhesive strength of about 4 to about 15 MPa, or about 4 to about 10 MPa, or about 5 to about 7 MPa, or a combination thereof; A hardness of at least 5H when measured according to ASTM D3363; and / or A hardness of about 6H to about 8H, or about 8H; The coating according to claim 59, having the above properties.
63. Use of the coating composition according to claim 59 for forming a coating on a substrate, Optionally, The substrate is the surface of a marine vessel, such as a boat or a ship, or the surface of marine equipment, such as a sensor or a propeller; and / or The substrate is the surface of a propeller, Use of the coating composition according to claim 59.
64. Use of a coating comprising a reaction product of a coating composition according to any one of claims 48 to 56 and a curing agent for reducing cavitation, or a reaction product of a coating composition according to any one of claims 48 to 56 and a curing agent composition according to claim 57 or 58 for reducing cavitation.