Zinc-rich epoxy coating

Abstract

The present disclosure relates to a coating composition comprising a resin component including an epoxy resin and a petroleum resin, zinc particles in an amount of at least 65 wt % based on the total solids weight of the coating composition, a metal salt of phosphoric acid, and a curing agent. In addition, the present disclosure also relates to a multi-part coating form of the coating composition, a method for preparing the coating composition, and a substrate coated with the coating composition.

Description

Technical Field

[0001] Technical field The present disclosure relates to a corrosion-resistant zinc-rich epoxy resin-based coating composition. More specifically, the present disclosure relates to a corrosion-resistant coating composition having corrosion resistance, rapid drying and curing rates, and low density.

Background Art

[0002] background Corrosion-resistant coatings are widely used in various industrial fields to protect coated substrates from external erosion, and are particularly used to protect industrial structures such as iron and steel structures, for example, steel structural parts of bridges, petroleum refining equipment, petrochemical production equipment, power plant equipment, storage tanks, cranes, wind turbines, and civil buildings.

[0003] Such coatings may be based on various resin systems, such as silicates, epoxy resins, polyurethanes, polysiloxanes, alkyd resins, etc.

[0004] Furthermore, it has been found that in order to enhance the corrosion resistance of the coating, some metals, such as zinc, can be added to the primer deposited on the substrate. Metals such as zinc can act as sacrificial anode materials to protect steel or iron substrates acting as cathodes.

[0005] <000(0022>A coating having improved corrosion resistance and / or curing characteristics is desired.

Summary of the Invention

[0006] summary The present disclosure provides - a resin component containing an epoxy resin and a petroleum resin, and - zinc particles in an amount of at least 65% by weight based on the total solid weight of the coating composition, and - a metal salt of phosphoric acid, and -A coating composition comprising a curing agent is provided.

[0007] This disclosure consists of at least the following two parts:

[0008] Part A comprises a resin component, zinc particles, and a metal salt of phosphoric acid, wherein the resin component includes epoxy resin and petroleum resin, and the amount of zinc particles is at least 65% by weight based on the total solid weight of the coating composition. The present invention further provides a multipart coating composition comprising part B, which contains a curing agent.

[0009] This disclosure further provides a method for preparing a coating composition, comprising providing at least the resin components, zinc particles, a metal salt of phosphoric acid, and a curing agent described above, or providing Part A and Part B containing these components, respectively, and then mixing them.

[0010] Finally, the Disclosure also provides coating compositions of the Disclosure, in particular, coated substrates on steel and / or iron structures. [Modes for carrying out the invention]

[0011] Detailed description of disclosure For the purposes of the following detailed explanation, it should be understood that this disclosure may take various alternative forms and sequences of steps, unless expressly otherwise provided. Furthermore, except in any example, or unless otherwise indicated, all numbers representing quantities of components used herein and in the claims should be understood to be modified in all cases by the term “approximately.” Thus, unless shown to be contrary, the numerical parameters described herein and in the appended claims are approximations that may vary depending on the desired properties obtained by this disclosure. At the very least, and without attempting to limit the application of the equivalent view to the claims, each numerical parameter should be interpreted by applying the usual rounding technique in light of the number of significant figures reported.

[0011] While the numerical ranges and parameters representing the broad scope of this disclosure are approximations, the figures shown in specific examples are reported as accurately as possible. However, all figures inherently contain a certain degree of error that inevitably arises from the standard deviation observed in their respective test measurements.

[0012] Furthermore, it should be understood that any numerical range listed herein is intended to include all subranges contained therein. For example, the range "1 to 10" is intended to include all subranges between (and including) the stated minimum value of 1 and the stated maximum value of 10, i.e., a minimum value of 1 or greater and a maximum value of 10 or less.

[0013] In this application, unless otherwise specified, the use of the singular includes the plural, and the plural includes the singular. In addition, in this application, "and / or" may be explicitly used in certain cases, but unless otherwise specified, the use of "or" means "and / or." Furthermore, in this application, the use of "one (a)" or "one (an)" means "at least one" unless otherwise specified. For example, "one (an)" epoxy resin, "one (a)" petroleum resin, "one (a)" metal salt of phosphoric acid, "one (a)" curing agent, etc., refer to one or more of these items.

[0014] The coating compositions of this disclosure may, advantageously, be formulated as multipart coating compositions. In the case of a multipart coating composition, the coating composition of this disclosure comprises part A as a base component or binder of the coating.

[0015] The resin component of the coating compositions of this disclosure comprises an epoxy resin (also referred to herein as an epoxy compound). Suitable epoxy resins have two or more 1,2-epoxy groups. They may be liquid or solid. Generally, the epoxy equivalent of an epoxy resin is 100 to 2,000 g / equivalent, generally 150 to 500 g / equivalent, e.g., 170 to 350 g / equivalent, e.g., 180 to 300 g / equivalent. Those skilled in the art will understand that epoxy equivalent means the number of grams of epoxy resin containing one equivalent of epoxy groups. Suitable liquid epoxy resins for this disclosure have relatively high viscosity and relatively low epoxy equivalent. Liquid epoxy resins used in this disclosure may have a viscosity of 8,000 to 16,000 cps at 25°C, such as 10,000 to 12,000 cps. Viscosity is measured using a Brookfield viscometer, spindle 7, at 100 rpm.

[0016] In addition, suitable epoxy resins may be saturated or unsaturated, cyclic or acyclic, aliphatic, alicyclic, aromatic, or heterocyclic. They may also contain substituents such as halogens, hydroxyls, and / or ether groups.

[0017] Examples of epoxy resins include polyepoxides having more than 1, for example, 2 1,2-epoxy equivalents, i.e., having an average of 2 epoxy groups per molecule. Polyepoxides commonly used as epoxy resins are polyglycidyl ethers of cyclic polyols, such as polyglycidyl ethers of polyphenols like bisphenol A, resorcinol, hydroquinone, benzenedimethanol, phloroglucinol, and catechol; or polyglycidyl ethers of alicyclic polyols, particularly alicyclic polyols such as 1,2-cyclohexanediol, 1,4-cyclohexanediol, 2,2-bis(4-hydroxylcyclohexyl)propane, 1,1-bis(4-hydroxylcyclohexyl)ethane, 2-methyl-1,1-bis(4-hydroxylcyclohexyl)propane, 2,2-bis(4-hydroxyl-3-tert-butylcyclohexyl)propane, 1,3-bis(methylol)cyclohexane, and 1,2-bis(methylol)cyclohexane. Particularly preferred aliphatic polyols include trimethylpentylene glycol and neopentylene glycol.

[0018] The epoxy resins of this disclosure may include, for example, those based on diglycidyl ethers such as bisphenol A, bisphenol F, glycerin, and novolac. The epoxy resins of this disclosure include those based on bisphenol A, bisphenol F, or mixtures thereof. Exemplary and suitable polyepoxides are described in U.S. Patent No. 4,681,811, column 5, lines 33-58, the portion referenced is incorporated herein by reference.

[0019] Suitable commercially available epoxy resins include Shell EPON 828 (bisphenol A-epichlorohydrin epoxy resin) and / or blends of this resin with difunctional epoxide reactive diluents, such as neopentylene glycol diglycidyl ether, resorcinol diglycidyl ether, and cyclohexanedimethanol diglycidyl ether; bisphenol A type liquid epoxy resins such as NPEL-128E; bisphenol A solid epoxy resins such as YD-011X75; bisphenol F epoxy resins, namely Shell EPON DPL 862 (bisphenol F-epichlorohydrin epoxy resin); and epoxy novolac resins such as EPARLOY 8250 (epoxy novolac resin) from CVC (Cherry Hill, NJ), Araldite EPN 1139 from Ciba Geigy, and DEN438 from Dow Chemical. Suitable non-aromatic epoxy resins include diglycidyl ethers of hydrogenated cyclohexanedimethanol and hydrogenated bisphenol A type epoxy resins, such as EPON 1510, EPON 4080E, HELOXY 107, and EPON 1513 (hydrogenated bisphenol A-epichlorohydrin epoxy resin) from Shell Chemical (Houston, Texas), Santolink LSE-120 from Monsanto (Springfield, Mass), EPODIL 757 (cyclohexanedimethanol diglycidyl ether) from Pacific Anchor (Allentown, Pa), Araldite XUGY358 and PY327 from Ciba Geigy (Hawthorne, New York), EPIREZ 505 from Rhone-Poulene (Louisville, Ky), AROFLINT 393 and 607 from Reichold (Pensacola, Florida), and Union Carbide ERL4221 from Tarrytown, New York is one example. Other suitable non-aromatic epoxy resins include DER 732 and DER 736.

[0020] The amount of epoxy resin in the coating composition described herein may be 3 - 25 wt%, such as 5 - 20 wt% or 7 - 15 wt%, based on the total weight of the coating composition. The coating composition may include both liquid epoxy resin and solid epoxy resin as the epoxy resin component. Both the liquid epoxy resin and the solid epoxy resin may include those as described above, such as bisphenol A and / or F type epoxy resin. Based on the total weight of the coating composition, the amount of the liquid epoxy resin may be 0.5 - 15 wt%, such as 1 - 10 wt% or 1 - 7 wt%, while the amount of the solid epoxy resin may be 1 - 20 wt%, such as 2 - 15 wt% or 2 - 12 wt%.

[0021] Furthermore, the resin component of the coating composition described herein includes petroleum resin. Petroleum resin is also known as hydrocarbon resin. Petroleum resin is a thermoplastic resin produced from C5 and C9 fractions generated from petroleum cracking by pretreatment, polymerization, distillation, and similar processes. Generally, petroleum resin includes aliphatic or alicyclic resins based on C5 or alicyclic dienes (such as dicyclopentadiene), and aromatic components based on C9 such as vinyltoluene or indene or aromatic resins and mixtures thereof. In some cases, petroleum resin also includes their hydrogenated products, namely hydrogenated petroleum resins such as C5 hydrogenated petroleum resin or C9 hydrogenated petroleum resin. Petroleum resin can also include modified petroleum resin, which is a low-viscosity liquid resin and, in contrast to general petroleum resin, contains inert hydroxyl in its aromatic functional group and can be used in solvent-based, non-solvent-based or high-solid-containing epoxy systems. The petroleum resin and modified petroleum resin used in accordance with the present disclosure are commercially available.

[0022] The amount of petroleum resin in the coating composition may be >0 (such as 0.1 or 0.5, etc.) - 10 wt%, such as 1 - 8 wt% or 1.5 - 5 wt%, based on the total weight of the coating composition.

[0023] In the coating composition according to the present disclosure, the weight ratio of epoxy resin to petroleum resin is 3 to 8:1, for example, 6:1, and may also be 2 to 10:1. Adding or mixing petroleum resin into the resin component containing epoxy resin, particularly in accordance with the above ratio, the coating composition can have a significantly improved hydrophilic and hydrophobic balance compared to those having only epoxy resin.

[0024] According to the present disclosure, the coating composition also contains zinc particles. In particular, the amount is at least 65% by weight based on the total solid weight of the coating composition. As used herein, "particles" means materials in the form of particles such as powders or dusts and flakes, and may be in the form of any shape, such as spherical, elliptical, cubic, rod-shaped, disk-shaped, prism-shaped, etc.

[0025] As used herein, "zinc" or "zinc particles" means metal particles substantially consisting of individual zinc particles or having a high zinc purity. Suitable purity of zinc particles generally refers to at least 94%, such as at least 96% or at least 98% or 99% of metallic zinc, based on the total weight of the particles, such as metal particles commercially available as zinc powder or zinc dust, and also includes metal particles having up to 100% of metallic zinc. Any portion of the particles used herein that is not zinc can be a coating layer of other metal elements or their compounds, such as particles formed of zinc and / or alloy materials. Suitable zinc particles can comply with, for example, the zinc powder specifications according to Type II or Type III of ASTM D520. In addition, particles of zinc alloys substantially based on zinc as a primary metal can also be used as the zinc particles of the present disclosure as long as they contain at least 94% of metallic zinc based on the total weight of the particles. Accordingly, alloys having zinc as a primary metal but containing a significant amount of other metal elements, such as more than 6%, for example, zinc alloys containing less than 94% of zinc, such as 50% by weight or more and generally 90%, are not included in the scope of "zinc" or "zinc particles" of the present disclosure.

[0026] The average particle size of zinc particles may be at least 2 μm, at least 5 μm, at least 5.5 μm, at least 6 μm, at least 1 μm, and may be 30 μm or less, 20 μm or less, 10 μm or less, 8 μm or less, or 150 μm or less. The average particle size of zinc particles may be 2 to 30 μm, 5 to 20 μm, 5.5 to 10 μm, 6 to 8 μm, or 1 to 150 μm. The choice of particle size may depend on the expected viscosity and application characteristics of the coating composition. The average particle sizes reported herein are those provided by the zinc particle manufacturers and can be measured by several known methods in the art, such as laser diffraction.

[0027] Based on the total solid weight of the coating composition, the coating composition may contain at least 70% by weight of zinc particles, at least 75% by weight of zinc particles, at least 80% by weight of zinc particles, at least 85% by weight of zinc particles, at least 65% by weight of zinc particles, and may contain 90% or less by weight of zinc particles, 85% or less by weight of zinc particles, and 95% or less by weight of zinc particles. The coating composition of the present disclosure may also contain zinc alloy particles having a zinc content of less than 94%, or other metal particles such as aluminum or aluminum alloys, but the coating composition preferably contains them in very small amounts, such as 5%, 4%, 3%, or 1% or less based on the total solid weight of the coating composition, and the composition may also not contain any other metal particles, including metal elements (i.e., zero valence) and metal alloys of other metals.

[0028] In addition, zinc particles may be surface-treated to modify their surface. Surface-treated zinc particles may include a pre-treatment layer formed by exposing the zinc particles to a pre-treatment composition. As used herein, the term “pre-treatment composition” refers to a composition that, upon contact with a zinc material, reacts with the material surface, chemically alters the material surface, and bonds to it to form a protective layer. The pre-treatment composition used to modify the surface of zinc particles may include any known in the art for pre-treating zinc materials.

[0029] Furthermore, according to this disclosure, metal salts of phosphoric acid are also used in coating compositions. “Salt of phosphoric acid” means an inorganic salt containing the phosphorus element in the anionic acid group, including phosphates, phosphates, hypophosphates, hydrogen phosphates, dihydrogen phosphates, hydrogen phosphites, dihydrogen phosphites, dihydrogen phosphites, polyphosphates, or polyphosphates, with phosphates, polyphosphates, and hydrogen phosphate being preferred. Metallic (such as molybdenum) or nonmetallic (such as silicon) modified forms, such as phosphatesilicates, can also be used as salts of phosphoric acid. Metals in the cationic portion of metal salts of phosphoric acid include zinc, aluminum, magnesium, calcium, strontium, zirconium, iron, and barium. It may be desirable to exclude alkali metals from such metals forming the metal salt.

[0030] Specific examples of suitable metal salts of phosphoric acid include zinc phosphate, aluminum tripolyphosphate, strontium aluminum polyphosphate, zirconium hydrogen phosphate, and silicon (silicate, etc.) modified phosphates or polyphosphates, such as calcium strontium zinc phosphatesilicate. Metal salts of phosphates such as zinc phosphate are particularly preferred.

[0031] When using metal phosphate in a zinc-rich epoxy resin-based coating composition, particularly when, for example, at least 65% by weight, at least 70% by weight, at least 75% by weight, or at least 80% by weight of zinc particles are used in combination with the metal phosphate, better long-term corrosion resistance can be obtained compared to other coatings teaching this combination. In addition, controlling the weight ratio of metal phosphate to zinc particles in the range of 1:20 to 1:60, such as 1:25 to 1:45, has been found to be particularly advantageous, especially when the amount of zinc particles exceeds 75% by weight or is greater than 75% by weight.

[0032] The coating composition also contains a curing agent component. A suitable curing agent component for epoxy resins may include an amine component. The amine component may include any compound that can act as a nitrogen source, such as proteins, polypeptides, amino acids, organic amines, polyamines, ammonia, ammonium salts of monomeric polycarboxylic acids, ammonium salts of polymerized polycarboxylic acids, ammonium salts of inorganic acids, polyetheramines, polyamides, adducts thereof including epoxy resins such as bisphenol A solid epoxy resin, and mixtures thereof.

[0033] Suitable curing agents include, for example, polyamines. Non-limiting examples of polyamine curing agents include primary or secondary diamines or polyamines, where the group linked to the nitrogen atom may be saturated or unsaturated aliphatic, alicyclic, aromatic, aromatically substituted aliphatic, aliphatic-substituted aromatic, and heterocyclic. Non-limiting examples of suitable aliphatic and alicyclic diamines include 1,2-ethylenediamine, 1,2-propylenediamine, 1,8-octanediamine, isophoronediamine, and propane-2,2-cyclohexylamine. Non-limiting examples of suitable aromatic polyamines include phenylenediamine and toluenediamine, such as meta-xylylenediamine, o-phenylenediamine, and p-toluenediamine. Multicore aromatic diamines such as 4,4'-biphenyldiamine, methylenediphenylamine, and chloromethylenediphenylamine are also suitable.

[0034] Suitable aliphatic diamines include, but are not limited to, ethylenediamine, 1,2-diaminopropane, 1,4-diaminobutane, 1,3-diaminopentane, 1,6-diaminohexane, 2-methyl-1,5-pentanediamine, 2,5-diamino-2,5-dimethylhexane, 2,2,4- and / or 2,4,4-trimethyl-1,6-diaminohexane, 1,11-diaminoundecane, 1,12-diaminododecane, 1,3- and / or 1,4-cyclohexanediamine, and 1-amino-3,3,5-trimethyl-5-aminometh Examples include 2-cyclohexane, 2,4- and / or 2,6-hexahydrotoluenediamine, 2,4'- and / or 4,4'-diamino-dicyclohexylmethane, and 3,3'-dialkyl4,4'-diamino-dicyclohexylmethane (such as 3,3'-dimethyl-4,4'-diamino-dicyclohexylmethane and 3,3'-diethylene-4,4'-diamino-dicyclohexylmethane), 2,4- and / or 2,6-diaminotoluene, and 2,4'- and / or 4,4'-diaminodiphenylmethane, or mixtures thereof. Alicyclic diamines are commercially available from Huntsman Corporation (Houston, TX) under the JEFFLINK name, such as JEFFLINK 754. Further aliphatic cyclic polyamines may be used, such as DESMOPHEN NH 1520, available from Covestro AG, and / or CLEARLINK 1000, a secondary aliphatic diamine available from Dorf Ketal. POLYCLEAR 136 (available from BASF / Hansen Group LLC), a reaction product of isophorone diamine and acrylonitrile, is also preferred. Other exemplary preferred polyamines are described in U.S. Patent No. 4,046,729, column 6, lines 61-7, line 26, and U.S. Patent No. 3,799,854, column 3, lines 13-50, the portions of which are incorporated herein by reference. Additional polyamines, such as ANCAMINE polyamine, available from Evonik Industries, may also be used.

[0035] Suitable polyamides include any of the polyamides known in the art. Polyamides used as curing agents are typically products formed by the condensation of a dimer acid (or ester) and a polyamine. For example, ANCAMIDE polyamide, available from Evonik Industries.

[0036] The curing agent may also contain a polyetheramine. A polyetheramine is a compound having a polyether main chain structure and further containing an amine group as a terminal active functional group. Polyetheramines are obtained by amine-forming polyethylene glycol, polypropylene glycol, or ethylene glycol / propylene glycol copolymer under high temperature and pressure. By selecting different polyoxyalkyl structures, the reactivity, toughness, viscosity, hydrophilicity, and other properties of the polyetheramine can be adjusted. The amine group provides polyetheramines with reaction properties with various compounds. Polyether monoamines that may be used in this disclosure include polyether monoamines, polyether diamines, polyether triamines, and the like. Specifically, polyetheramines used in this disclosure may include polyoxide ethylenediamine, polyoxide propylenediamine, polyoxide butylenediamine, and polyoxide ethylenetriamine, polyoxide propylenetriamine, and polyoxide butylenetriamine. Examples of commercially available polyetheramines that may be used in this disclosure include, for example, the Jeffamine series products. Examples of such polyetheramines include amination-propoxylated pentaerythritol such as JEFFAMINE XTJ-616, and those represented by formulas (IV) to (VI).

[0037] According to formula (IV), polyetheramine may include, or may be represented by, [ka] In the equation, y = 0 to 39 and x + z = 1 to 68.

[0038] Suitable amine-containing compounds represented by formula (IV) of this disclosure include, but are not limited to, amine-terminated polyethylene glycols such as the JEFFAMINE ED series commercially available from Huntsman Corporation, including JEFFAMINE HK-511, JEFFAMINE ED-600, JEFFAMINE ED-900, and JEFFAMINE ED-2003, as well as amine-terminated polypropylene glycols such as the JEFFAMINE D series from Huntsman Corporation, including JEFFAMINE D-230, JEFFAMINE D-400, JEFFAMINE D-2000, and JEFFAMINE D-4000.

[0039] According to formula (V), polyetheramine may include, or may be represented by, [ka] In the equation, each p is independently either 2 or 3.

[0040] Suitable amine-containing compounds represented by formula (V) of this disclosure include, but are not limited to, amine-terminated polyethylene glycol-based diamines such as the Huntsman Corporation's JEFFAMINE EDR series, including JEFFAMINE EDR-148 and JEFFAMINE EDR-176.

[0041] According to formula (VI), polyetheramine may include, or may be represented by, [ka] In the formula, R is H or C2H5, m=0 or 1, and a+b+c=5 to 85.

[0042] Suitable amine-containing compounds represented by formula (VI) of this disclosure include, but are not limited to, amine-terminated propoxylated trimethylolpropane or glycerol, such as the Jeffamine T series from Huntsman Corporation, including JEFFAMINE T-403, JEFFAMINE T-3000, and JEFFAMINE T-5000.

[0043] The amine component may also optionally include other functional groups or moieties, such as a polyamine containing 2,4,6-tris(dimethylaminomethyl)phenol.

[0044] To achieve faster curing and drying rates, adducts of the above-mentioned amine compounds, such as polyetheramines, polyamides, and / or polyamines (such as aliphatic diamines, alicyclic diamines, or aromatic diamines as described above), and epoxy resins can be advantageously used as curing agent components. The epoxy resin may be one of the above-mentioned epoxy compounds, such as those based on bisphenol F or bisphenol A.

[0045] The curing agent component of the coating composition may also optionally include a curing accelerator. The curing accelerator is used to accelerate the reaction between the amine component and the epoxy resin. Exemplary curing accelerators include, but are not limited to, salicylic acid.

[0046] The amount of curing accelerator in the coating composition of this disclosure may be 0 to 3% by weight, such as 1 to 2.5% by weight or 1.5 to 2% by weight, based on the total weight of the curing agent components of the coating composition.

[0047] The coating compositions of this disclosure may also contain one or more solvents. Solvents commonly used in the coatings field may be used in this disclosure. Specific examples of solvents, but are not limited to, include propylene glycol monomethyl ether acetate and its derivatives, acetone, amyl propionate, anisole, benzene, butyl acetate, cyclohexane, dialkyl ethers of ethylene glycol, diethylene glycol dibenzoate, dimethyl sulfoxide, dimethylformamide, dimethoxybenzene, ethyl acetate, isopropanol, isobutanol, methylcyclohexanone, cyclopentanone, methyl ethyl ketone, methyl isobutyl ketone, methyl propionate, propylene carbonate, tetrahydrofuran, toluene, xylene, benzyl alcohol, 2-methoxyethyl ether, 3-propylene glycol methyl ether, and mixtures thereof.

[0048] The amount of one or more solvents in the coating composition of this disclosure may be 5 to 15% by weight, such as 7 to 12% by weight or 8 to 11% by weight, based on the total weight of the coating composition.

[0049] The coating composition may also include, but is not limited to, one or more additives, including thixotropes, wetting agents and dispersants, fillers, pigments, and other additives commonly used in coating compositions.

[0050] Thixotropes are used to improve and / or maintain the rheology of coating compositions, and when used, can prevent the sedimentation of zinc powder particles and fillers in the coating. Examples of thixotropes include colloidal silicates, hydrated aluminum silicate (bentonite), aluminum tristearate, aluminum monostearate, xanthan gum, chrysotile, calcined silica, hydrogenated castor oil, organically modified clay, polyamide wax, and polyethylene wax. The amount of thixotrope can be selected by those skilled in the art according to the actual needs. For example, the amount of thixotrope in the coating composition of this disclosure may be 0.5 to 1.5% by weight, such as 0.6 to 1.1% by weight, based on the total weight of the coating composition.

[0051] Wetting agents and dispersants, when used, can improve the dispersibility of zinc particles and fillers in the coating. Suitable examples of wetting agents and dispersants include lecithin, amine alkylated polyhydroxy acid amides, polyesters having amino-substituted end groups, block copolymers, and ethylene polymers. The amount of wetting agents and dispersants in the coating composition of this disclosure may be 0.1 to 0.5% by weight, such as 0.2 to 0.4% by weight, based on the total weight of the coating composition.

[0052] The coating composition, in particular part A of the composition described below, may contain fillers other than zinc particles. Suitable fillers include, but are not limited to, talc, silicates, mica, montmorillonite, kaolin, diatomaceous earth, vermiculite, natural and synthetic zeolites, calcium silicate, aluminum silicate, sodium aluminum silicate, hollow microspheres such as hollow glass microspheres, barium sulfate, and calcium carbonate. The coating composition of this disclosure, in particular part A of the composition, may contain talc powder, silicates, and / or hollow microspheres such as hollow glass microspheres as fillers. The coating composition, in particular part A of the composition, may optionally contain barium sulfate as a filler. The amount of filler in the coating composition of this disclosure may range from 2 to 8% based on the total weight of the coating composition. The content of hollow microspheres such as hollow glass microspheres may be 1 to 5% based on the total weight of the composition.

[0053] Examples of pigments and / or pigment compositions include, but are not limited to, carbazole dioxazine crude pigments, azo, monoazo, diazo, naphthol AS, salts (lake), benzimidazolon, condensates, metal complexes, isoindolinone, isoindoline and polycyclic phthalocyanines, quinacridone, perylene, perinone, diketopyrrolopyrrole, thioindigo, anthraquinone, indanthrone, anthrapyrimidine, flavanthrone, pyranthrone, ansanthrone, dioxazine, triarylcarbonium, quinophthalone pigments, diketopyrrolopyrrole red ("DPPBO red"), titanium dioxide, iron oxide, carbon black, carbon fiber, graphite, other conductive pigments and / or fillers, and mixtures thereof.

[0054] The amount of pigment and / or pigment composition in the coating composition may be in the range of 0.5 to 5% by weight, such as 0.5 to 3% by weight, based on the total weight of the coating composition.

[0055] The coating compositions of this disclosure may be formulated in a multipart form. Multipart system is a term known in the coatings field and means that the components of a coating composition are formulated into multiple parts or components that are packaged in separate containers, such as waterproof containers. A multipart coating composition may consist of at least two parts:

[0056] Part A comprises the resin component defined above, zinc particles, and a metal salt of phosphoric acid, wherein the resin component includes epoxy resin and petroleum resin, and the amount of zinc particles is at least 65% by weight based on the total solid weight of the coating composition. Part B, which contains a hardening agent, is included.

[0057] The method for preparing Part A of the coating composition is known to those skilled in the art. For example, the components of Part A are mixed at room temperature or slightly above room temperature and stirred in a container until a suitable viscosity is achieved. Similarly, the method for preparing Part B of the coating composition is known to those skilled in the art and may be carried out in the same manner as the preparation method for Part A described above.

[0058] Before using the coating compositions described herein, the components are mixed. In the case of multipart coating compositions, part A and part B, and any other part are mixed. Part A and part B may be mixed in a stoichiometric ratio of epoxy groups to amine groups of 1:0.5 to 1:0.9. The resulting coating composition is then applied to a substrate. There are no limitations on the method of applying the coating compositions of this disclosure to a substrate. For example, application methods may include brush coating, spray coating, dip coating, roller coating, curtain coating, and the like.

[0059] The substrates to which the coating compositions of this disclosure may be applied may be metal substrates. Metal substrates include various steel substrates, iron substrates, aluminum substrates, and the like. Advantageously, the coating compositions of this disclosure may be applied to these substrates as a primer or base coating. The substrates may be part of a structure or part of a vehicle. As used herein, “structure” means buildings, bridges, transport infrastructure, oil rigs, oil platforms, water towers, power transmission towers, support structures, wind turbines, walls, piers, docks, dikes, dams, shipping containers, trailers, battery components, batteries, and any part of any metal structure exposed to a corrosive environment. As used herein, “vehicle” means, in its broadest sense, but not limited to, all types of vehicles, including cars, trucks, buses, tractors, harvesters, heavy machinery, vans, golf carts, motorcycles, bicycles, railway cars, subway cars, airplanes, helicopters, and boats of all sizes.

[0060] The following examples (exemplifications) are provided for the purpose of providing a more detailed explanation. However, while these examples are used to illustrate the present disclosure, they should not be considered as limiting to their details. All parts and percentages in the following examples and descriptions are by weight unless otherwise indicated. example [Table 0]

[0061] Preparation of binder part A1 The preparation procedure for binder part A1 was as follows: In a container at room temperature, 10 g of liquid bisphenol A epoxy resin (NPEL-128E, commercially available from Nan Ya Plastics), 100 g of solid bisphenol A epoxy resin (YD-011X75, commercially available from KUKDO CHEMICAL), 30 g of xylene, 17.7 g of propylene glycol monomethyl ether acetate, and 7.3 g of isobutanol were uniformly mixed. Then, 18.1 g of petroleum resin (SK 120, commercially available from Taiwan Yuen Liang) was added while stirring and completely dissolved. Next, 5.3 g of polyamide wax (Crayvallac ultra, commercially available from ARKEMA) and 5.3 g of organic bentonite (BENTONE SD-2, commercially available from ELEMENTIS SPECIALTIES) were added slowly while stirring, maintaining the temperature below 40°C, until uniformly dispersed. 2.7 g of soy lecithin (commercially available from Cargill, TOPCITHIN 50), 19.5 g of zinc phosphate (commercially available from Jiangsu Shen Long Zinc Co. Ltd.), and 771.9 g of zinc powder (commercially available from Jiangsu Shen Long Zinc Co. Ltd., HX600 to II) were added while stirring for 30 minutes, maintaining a temperature of 55-60°C. Finally, 38.7 g of xylene and 19.5 g of hollow glass microspheres (commercially available from 3M, GLASS BUBBLES VS5500) were added while stirring until uniformly dispersed.

[0062] Preparation of binder part A2 (comparison) The preparation procedure for the binder part A1 of the coating composition of this disclosure was carried out in the same manner as described above, and the weight portions of each component are shown in Table 1. The difference is that zinc phosphate is not used and the amount of petroleum resin is increased.

[0063] Preparation of binder part A3 The preparation procedure for binder part A3 was as follows: In a container at room temperature, 10 g of bisphenol A liquid epoxy resin (NPEL-128E, commercially available from Nan Ya Plastics), 119.5 g of bisphenol A solid epoxy resin (YD-011X75, commercially available from KUKDO CHEMICAL), 30 g of xylene, 17.7 g of propylene glycol monomethyl ether acetate, and 7.3 g of isobutanol were uniformly mixed. Then, 18.1 g of petroleum resin (SK 120, commercially available from Taiwan Yuen Liang) was added while stirring and completely dissolved. 5.3 g of polyamide wax (Crayvallac ultra, commercially available from ARKEMA) and 5.3 g of organic bentonite (BENTONE SD-2, commercially available from ELEMENTIS SPECIALTIES) were added slowly while stirring, maintaining the temperature below 40°C, until uniformly dispersed. 2.7 g of soy lecithin (commercially available from Cargill, TOPCITHIN 50), 19.5 g of zinc phosphate (commercially available from Jiangsu Shen Long Zinc Co. Ltd.), and 800 g of zinc powder (commercially available from Jiangsu Shen Long Zinc Co. Ltd., HX600 to II) were added while stirring for 30 minutes, maintaining a temperature of 55-60°C. Finally, 45.1 g of xylene and 19.5 g of hollow glass microspheres (commercially available from 3M, GLASS BUBBLES VS5500) were added while stirring until uniformly dispersed.

[0064] Preparation of binder part A4 The procedure for the binder part A4 was as follows: In a container at room temperature, 42.5 g of liquid bisphenol A epoxy resin (NPEL-128E, commercially available from Nan Ya Plastics), 28.3 g of solid bisphenol A epoxy resin (YD-011X75, commercially available from KUKDO CHEMICAL), 30 g of xylene, 17.7 g of propylene glycol monomethyl ether acetate, and 7.3 g of isobutanol were uniformly mixed. Then, 18.1 g of petroleum resin (SK 120, commercially available from Taiwan Yuen Liang) was added while stirring and completely dissolved. 5.3 g of polyamide wax (Crayvallac ultra, commercially available from ARKEMA) and 5.3 g of organic bentonite (BENTONE SD-2, commercially available from ELEMENTIS SPECIALTIES) were added slowly while stirring, maintaining the temperature below 40°C, until uniformly dispersed. 2.7 g of soy lecithin (commercially available from Cargill, TOPCITHIN 50), 19.5 g of zinc phosphate (commercially available from Jiangsu Shen Long Zinc Co. Ltd.), and 752.4 g of zinc powder (commercially available from Jiangsu Shen Long Zinc Co. Ltd., HX600 to II) were added while stirring for 30 minutes, maintaining a temperature of 55-60°C. Finally, 41.4 g of xylene and 19.5 g of hollow glass microspheres (commercially available from 3M, GLASS BUBBLES VS5500) were added while stirring until uniformly mixed.

[0065] Preparation of binder part A5 (comparison) The preparation procedure for the binder of the coating composition of this disclosure, Part A4, was carried out in the same manner as described above, and the weight portions of each component are shown in Table 1. The difference is that zinc phosphate is not used and the amount of petroleum resin is increased.

[0066] Preparation of binder part A6 (comparison) The preparation procedure for the binder of the coating composition of this disclosure, Part A4, was carried out in the same manner as described above, and the weight portions of each component are shown in Table 1. The difference is that petroleum resin was not used.

[0067] Preparation of binder part A7 (comparison) The preparation procedure for the binder of the coating composition of this disclosure, Part A4, was carried out in the same manner as described above, and the weight portions of each component are shown in Table 1. The difference is that petroleum resin, zinc phosphate, and hollow glass microspheres were not used, but talc powder was added as a filler.

[0068] Preparation of binder parts A8 and A9 (comparison) The preparation procedure for the binder, Part A7, was carried out in the same manner as described above, and the weight portions of each component are shown in Table 1. The difference is that talc powder was added as a filler, and the amount of zinc particles was reduced accordingly.

[0069] The individual binder parts were prepared using the components and quantities shown in Table 1 below. [Table 1]

[0070] Hardener Part B1 The hardener part B1 was prepared using the components and quantities shown in Table 2 below. [Table 2]

[0071] The preparation procedure for curing agent part B1 was as follows: In an iron container at room temperature, the solvent xylene, isobutanol, and polyamide parts, along with 2,4,6-tris(dimethylaminomethyl)phenol, were added and mixed uniformly. The bisphenol A solid epoxy resin was added while stirring. Finally, the remaining solvent was added and mixed uniformly. The mixture was left at room temperature for at least 3 days before use.

[0072] Hardener Part B2 The curing agent part B2 was prepared using the components and quantities shown in Table 3 below. [Table 3]

[0073] The preparation procedure for curing agent part B2 was as follows: In a beaker at room temperature, the solvent xylene, isobutanol, and part of meta-xylenediamine were added and mixed uniformly. Bisphenol F epoxy resin was added while stirring, and the temperature was raised to 90-100°C and reacted for 1 hour. After lowering the temperature to 70-75°C, polyoxypropylene triamine, 2,4,6-tris(dimethylaminomethyl)phenol, benzyl alcohol, and the remaining solvent were added and mixed uniformly.

[0074] Hardener Part B3 The curing agent part B2 was prepared using the components and quantities shown in Table 4 below. [Table 4]

[0075] The preparation procedure for curing agent part B3 was as follows: In an iron container at room temperature, benzyl alcohol, the solvent xylene and isobutanol, polyamide, and 2,4,6-tris(dimethylaminomethyl)phenol were added and mixed uniformly. Bisphenol A liquid epoxy resin was added while stirring and mixed uniformly. The mixture was left at room temperature for at least 3 days before use.

[0076] Coating preparation example 1 The binder part A1 and the curing agent part B1 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.75, and the volume ratio of the binder part to the curing agent part was 85:15.

[0077] Coating preparation example 2 (comparison) The binder part A2 and the curing agent part B1 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.78, and the volume ratio of the binder part to the curing agent part was 85:15.

[0078] Coating preparation example 3 The binder part A3 and the curing agent part B2 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.76, and the volume ratio of the binder part to the curing agent part was 90:10.

[0079] Coating preparation example 4 The binder part A4 and the curing agent part B1 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.75, and the volume ratio of the binder part to the curing agent part was 77.5:22.5.

[0080] Coating preparation example 5 (comparison) The binder part A5 and the curing agent part B1 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.79, and the volume ratio of the binder part to the curing agent part was 80:20.

[0081] Coating preparation example 6 (comparison) The binder part A6 and the curing agent part B1 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.75, and the volume ratio of the binder part to the curing agent part was 80:20.

[0082] Coating preparation example 7 (comparison) The binder part A6 and the curing agent part B2 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.73, and the volume ratio of the binder part to the curing agent part was 90:10.

[0083] Coating preparation example 8 (comparison) The binder part A7 and the curing agent part B3 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.77, and the volume ratio of the binder part to the curing agent part was 80:20.

[0084] Coating preparation example 9 (comparison) At room temperature, the binder part A8 and the curing agent part B3 were combined. The stoichiometric ratio of the binder part to the curing agent part was 1:0.81, and the volume ratio of the binder part to the curing agent part was 80:20.

[0085] Coating preparation example 10 (comparative) The binder part A9 and the curing agent part B3 were combined at room temperature. The stoichiometric ratio of the binder part to the curing agent part was 1:0.87, and the volume ratio of the binder part to the curing agent part was 80:20.

[0086] Characteristic testing: 1. Drying characteristics test A blade applicator with an opening of 150 μm was used. The coating composition prepared as described above was blade-coated onto a glass bar. The drying properties of the coating were tested (ASTM D1640). The test results are shown in Table 5 below.

[0087] 2. Salt spray test ASTM B117 The individual coatings described above were applied to a 150mm x 75mm x 5mm (length x width x thickness) sandblasted Sa2.5 carbon steel panel, with a dry film thickness of 100 μm. The coating film was fully cured by drying at room temperature for 14 days. Salt spray tests were conducted according to ASTM B117. The test results are shown in Table 5 below.

[0088] 3. Moisture and heat resistance test ASTM D 2247 The individual coatings described above were applied to a 150mm x 75mm x 5mm (length x width x thickness) sandblasted Sa2.5 carbon steel panel, with a dry film thickness of 100 μm. The coating film was fully cured by drying at room temperature for 14 days. Humidity and heat resistance tests were conducted according to ASTM D 2247. The test results are shown in Table 5 below.

[0089] 4. Cycle aging test ISO12944-9 The individual coatings described above were applied to a 150mm × 75mm × 5mm (length × width × thickness) sandblasted Sa2.5 carbon steel panel, with a dry film thickness of 60 μm. Next, an epoxy intermediate coat was sprayed as a 170 μm dry film, followed by a polyurethane topcoat sprayed as a 50 μm dry film. The coated film was fully cured by drying at room temperature for 14 days. A 25-cycle aging test was conducted according to the conditions of ISO 12944-9. Each cycle of the aging test consisted of 72 hours of UVA (ISO 16474-3, Method A), 72 hours of salt spray testing (ISO 9227), and 24 hours of freezing at -20°C. The test results are shown in Table 5 below. [Table 5]

[0090] As can be seen from the various test results described above, the coating compositions of this disclosure can reduce the density of zinc-rich epoxy coatings and the amount of zinc powder, while simultaneously achieving considerable improvements in drying properties and corrosion resistance (salt spray test, humidity and heat resistance test, and cycle aging test) by optimizing the ratio of metal salts of phosphoric acid, petroleum resin, and epoxy resin, and in certain cases by further adding hollow glass microspheres.

[0091] Those skilled in the art will understand that modifications to this disclosure can be made without departing from the concepts disclosed in the preceding description. Therefore, it should be understood that the specific embodiments detailed herein are merely illustrative and not limiting to this disclosure. This disclosure will encompass the entire scope of the appended claims and their equivalents. In connection with the present invention, the following is further disclosed. [1] A coating composition, - Resin components including epoxy resin and petroleum resin, -Based on the total solid weight of the coating composition, at least 65% by weight of zinc particles, -Metal salts of phosphoric acid, - A coating composition comprising a curing agent. [2] The coating composition according to [1], characterized in that the coating composition contains at least 70% by weight of zinc particles, such as at least 75% by weight, more than 75% by weight, or at least 80% by weight. [3] The coating composition according to any one of the preceding claims, characterized in that the amount of the petroleum resin is greater than 0 (such as 0.1 or 0.5) to 10% by weight, such as 1 to 8% by weight or 1.5 to 5% by weight, based on the total weight of the coating composition. [4] The coating composition according to any one of the preceding claims, characterized in that the weight ratio of the epoxy resin to the petroleum resin is in the range of 2 to 10:1, such as 3 to 8:1 or 6:1. [5] The coating composition according to any one of the preceding claims, characterized in that the weight ratio of the metal salt of phosphoric acid to zinc particles is in the range of 1:20 to 1:60, such as 1:25 to 1:45. [6] The coating composition according to any one of the preceding claims, characterized in that the metal salt of phosphoric acid comprises phosphates, phosphates, hypophosphates, hydrogen phosphates, dihydrogen phosphates, hydrogen phosphites, dihydrogen phosphites, and polyphosphates, for example, silicon-modified phosphates or polyphosphates such as zinc phosphate, aluminum tripolyphosphate, strontium aluminum polyphosphate, zirconium hydrogen phosphate, silicates, for example, phosphate silicates such as calcium strontium zinc phosphatesilicate, or mixtures thereof. [7] The coating composition according to any one of the preceding claims, characterized in that the amount of epoxy resin is 3 to 25% by weight, such as 5 to 20% by weight or 7 to 15% by weight, based on the total weight of the coating composition, and / or the epoxy equivalent is 100 to 2,000 g / equivalent, such as 150 to 500 g / equivalent, 170 to 350 g / equivalent, or 180 to 300 g / equivalent. [8] The coating composition according to any one of the preceding claims, characterized in that the epoxy resin includes both a liquid epoxy resin and a solid epoxy resin, such as a liquid and solid bisphenol A type epoxy resin. [9] The coating composition according to [8], characterized in that, based on the total weight of the coating composition, the amount of the liquid epoxy resin is 0.5 to 15% by weight, such as 1 to 10% by weight or 1 to 7% by weight, and the amount of the solid epoxy resin is 1 to 20% by weight, such as 2 to 15% by weight or 2 to 12% by weight.

[10] The curing agent comprises a polyamine, a primary or secondary diamine, or a polyamine, wherein the group linked to the nitrogen atom is saturated or unsaturated aliphatic, alicyclic, aromatic, aromatically substituted aliphatic, aliphatic-substituted aromatic, and heterocyclic, for example, 1,2-ethylenediamine, 1,2-propylenediamine, 1,8-octanediamine, isophoronediamine, propane-2,2-cyclohexylamine, phenylenediamine, and toluenediamine, for example, meta-xylenediamine, o - Phenylenediamine and p-toluenediamine, 4,4'-biphenyldiamine, methylenediphenylamine and chloromethylenediphenylamine, or ethylenediamine, 1,2-diaminopropane, 1,4-diaminobutane, 1,3-diaminopentane, 1,6-diaminohexane, 2-methyl-1,5-pentanediamine, 2,5-diamino-2,5-dimethylhexane, 2,2,4- and / or 2,4,4-trimethyl-1,6-diaminohexa , 1,11-diaminoundecane, 1,12-diaminododecane, 1,3- and / or 1,4-cyclohexanediamine, 1-amino-3,3,5-trimethyl-5-aminomethyl-cyclohexane, 2,4- and / or 2,6-hexahydrotoluenediamine, 2,4'- and / or 4,4'-diamino-dicyclohexylmethane, and 3,3'-dialkyl4,4'-diamino-dicyclohexylmethane (3,3'-dimethyl-4,4' A coating composition according to any one of the preceding claims, characterized in that it may contain a polyamine adduct containing polyetheramine, polyamide, and / or epoxy resin, or a mixture thereof (such as -diamino-dicyclohexylmethane and 3,3'-diethylene-4,4'-diamino-dicyclohexylmethane), 2,4- and / or 2,6-diaminotoluene and 2,4'- and / or 4,4'-diaminodiphenylmethane.

[11] The coating composition according to any one of the preceding claims, characterized in that the coating composition further comprises 1 to 5% by weight of glass microspheres based on the total weight of the composition.

[12] A multipart coating composition, at least Part A comprises the resin component described in [1], zinc particles, and a metal salt of phosphoric acid, wherein the resin component comprises epoxy resin and petroleum resin, and the amount of zinc particles is at least 65% by weight based on the total solid weight of the coating composition. A multipart coating composition comprising part B, which contains the curing agent described in [1], and in which any suitable stoichiometric ratio of epoxy group to amine group, such as 1:0.5 to 0.9, may be used.

[13] The epoxy resin is saturated or unsaturated, cyclic or acyclic, aliphatic, alicyclic, aromatic or heterocyclic, unsubstituted or substituted, for example, halogen, hydroxyl, and / or ether groups; polyglycidyl ethers of cyclic polyols, for example, polyglycidyl ethers of polyphenols such as bisphenol A, resorcinol, hydroquinone, benzenedimethanol, phloroglucinol, and catechol, etc., having more than 1,2-epoxy equivalents of polyepoxide; or polyols, for example, alicyclic polyols, for example, alicyclic polyols, for example, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 2,2- The coating composition according to any one of the preceding claims, which may be bis(4-hydroxycyclohexyl)propane, 1,1-bis(4-hydroxycyclohexyl)ethane, 2-methyl-1,1-bis(4-hydroxycyclohexyl)propane, 2,2-bis(4-hydroxyl-3-tert-butylcyclohexyl)propane, 1,3-bis(methylol)cyclohexane and / or 1,2-bis(methylol)cyclohexane, trimethylpentylene glycol, and polyglycidyl ethers of neopentylene glycol; bisphenol A, bisphenol F, glycerin, diglycidyl ethers of novolac, or mixtures thereof.

[14] The coating composition according to any one of the preceding claims, wherein the petroleum resin comprises an aliphatic or alicyclic resin based on a alicyclic diene such as C5 or dicyclopentadiene, and / or an aromatic component based on C9 such as vinyltoluene, indene, or aromatic resins and mixtures thereof, or a hydrogenation product such as a C5 hydrogenated petroleum resin or a C9 hydrogenated petroleum resin, or a modified petroleum resin containing an inert hydroxyl in its aromatic functional group or mixture thereof.

[15] The coating composition according to any one of the preceding claims, wherein the zinc particles are at least 94% pure, such as at least 96% pure, at least 98% pure, at least 99% pure, or 100% pure, and / or have an average particle size of at least 1 μm, such as at least 2 μm, at least 5 μm, at least 5.5 μm, or at least 6 μm, and may be 150 μm or less, such as 30 μm or less, 20 μm or less, 10 μm or less, or 8 μm or less, and may be 1 to 150 μm, such as 2 to 30 μm, or 5 to 20 μm, 5.5 to 10 μm, or 6 to 8 μm, and / or may be present in the coating composition in an amount of 95% by weight or less, such as 90% by weight or 85% by weight or less, based on total weight, and / or the zinc particles are surface-treated, for example, with a pretreatment composition, before being incorporated into the coating composition.

[16] The coating composition according to any one of the preceding claims, wherein the composition contains 5% by weight or less of metal particles other than zinc, such as 4% by weight, 3% by weight, 2% by weight, or 1% by weight or less (including zero).

[17] The coating composition according to any one of the preceding claims, wherein the metal salt of phosphoric acid does not contain an alkali metal salt.

[18] A coating composition according to any one of the preceding claims, further comprising a curing accelerator, a solvent, a thixotrope, a wetting agent and a dispersant, a filler, a pigment, and any mixture thereof.

[19] A method for preparing a coating composition according to any one of the preceding claims, comprising mixing a resin component, zinc particles, a metal salt of phosphoric acid, and a curing agent according to any one of the preceding claims, or mixing parts A and B containing these components according to any one of the preceding claims.

[20] A substrate coated with any of the coating compositions described in [1] to

[19] .

[21] The substrate according to

[20] , wherein the substrate is a metal.

[22] The substrate according to

[21] , wherein the substrate comprises iron, steel, and / or aluminum, and / or alloys thereof.

[23] The substrate according to any one of

[20] to

[22] , wherein the substrate includes a part of a vehicle.

[24] The substrate according to any one of

[20] to

[22] , wherein the substrate comprises a part of the structure.

Claims

1. A coating composition, - Resin components including epoxy resin and petroleum resin, - Based on the total solid weight of the coating composition, at least 65% by weight of zinc particles, - Metal salts of phosphoric acid, - Hardener and, - Based on the total weight of the coating composition, an organic solvent is included in an amount of 5 to 15% by weight, A coating composition comprising, The weight ratio of the metal salt of phosphoric acid to zinc particles is 1:20 to 1:

45. The epoxy resin includes both liquid epoxy resin and solid epoxy resin. The amount of solid epoxy resin is 2 to 12% by weight, based on the total weight of the coating composition. The amount of the petroleum resin is 0.5 to 10% by weight, based on the total weight of the coating composition. A coating composition in which the weight ratio of the epoxy resin to the petroleum resin is in the range of 2 to 10:

1.

2. The coating composition according to claim 1, characterized in that the coating composition contains at least 70% by weight of zinc particles.

3. The coating composition according to claim 1 or 2, characterized in that the amount of the petroleum resin is 1 to 8% by weight based on the total weight of the coating composition.

4. The coating composition according to any one of claims 1 to 3, characterized in that the weight ratio of the epoxy resin to the petroleum resin is in the range of 3 to 8:

1.

5. The coating composition according to any one of claims 1 to 4, characterized in that the metal salt of phosphoric acid comprises phosphate, phosphate, hypophosphate, hydrogen phosphate, dihydrogen phosphate, hydrogen phosphite, dihydrogen phosphite, and polyphosphate, or a mixture thereof.

6. The coating composition according to any one of claims 1 to 5, wherein the amount of epoxy resin is 3 to 25% by weight based on the total weight of the coating composition.

7. A coating composition according to any one of claims 1 to 6, characterized in that the epoxy equivalent of the epoxy resin is 150 to 500 g / equivalent.

8. The coating composition according to any one of claims 1 to 7, characterized in that the amount of liquid epoxy resin is 0.5 to 15% by weight, based on the total weight of the coating composition.

9. The coating composition according to any one of claims 1 to 8, characterized in that the curing agent comprises an adduct of an amine and an epoxy resin.

10. The coating composition according to any one of claims 1 to 9, characterized in that the coating composition further comprises 1 to 5% by weight of glass microspheres based on the total weight of the composition.

11. The coating composition is a multipart coating composition, and the coating composition is Part A comprises the resin component, the zinc particles, and the metal salt of phosphoric acid, Part B, which includes the aforementioned curing agent, Moreover, the stoichiometric ratio of epoxy groups contained in the epoxy resin to amine groups contained in the curing agent is 1:0.5 to 0.

9. Moreover, both Part A and Part B include the organic solvent portion. The coating composition according to any one of claims 1 to 10.

12. The coating composition according to any one of claims 1 to 11, wherein the epoxy resin is saturated or unsaturated, cyclic or acyclic, aliphatic, alicyclic, aromatic or heterocyclic, unsubstituted or substituted.

13. The coating composition according to any one of claims 1 to 12, wherein the petroleum resin comprises an aliphatic or alicyclic resin based on C5 or an alicyclic diene, and / or an aromatic component based on C9, or a C5 hydrogenated petroleum resin or a C9 hydrogenated petroleum resin, or a modified petroleum resin containing inert hydroxyl in its aromatic functional group or a mixture thereof.

14. The coating composition according to any one of claims 1 to 13, wherein the zinc particles are at least 94% pure and / or have an average particle size of 150 μm or less with at least 1 μm and / or can be present in the coating composition in an amount of 95% by weight or less based on total weight and / or the zinc particles are surface-treated with a pretreatment composition before being incorporated into the coating composition.

15. The coating composition according to any one of claims 1 to 14, wherein the composition contains 5% by weight or less of metal particles other than zinc.

16. The coating composition according to any one of claims 1 to 15, wherein the metal salt of phosphoric acid does not contain an alkali metal salt.

17. A coating composition according to any one of claims 1 to 16, further comprising a curing accelerator, a thixotrope, a wetting agent and a dispersant, a filler, a pigment, and any mixture thereof.

18. A method for preparing a coating composition according to any one of claims 1 to 17, comprising mixing a resin component, zinc particles, a metal salt of phosphoric acid, and a curing agent according to any one of claims 1 to 17.

19. A substrate coated with the coating composition according to any one of claims 1 to 18.

20. The substrate according to claim 19, wherein the substrate is a metal.

21. The substrate according to claim 20, wherein the substrate comprises iron, steel, and / or aluminum, and / or alloys thereof.

22. The substrate according to any one of claims 19 to 21, wherein the substrate includes a part of a vehicle.

23. The substrate according to any one of claims 19 to 21, wherein the substrate includes a part of the structure.

Images