Single layer coating with edge covering properties

Abstract

A coating composition including a binder resin, a crosslinker, one or more fillers, and an acid functional urethane rheology modifier is provided. The binder resin may be at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin. The filler may be at least one of a pigment, a colorant, and an additive. The coating composition has a plate flow less than 50 mm measured at 191oC, as determined by ASTM D4242 (2017) and a PCI value of greater than 7, as measured by ASTM D3451, section 32.8.2 (2017).

Description

SINGLE LAYER COATING WITH EDGE COVERING PROPERTIES CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No.63 / 657,570 entitled “SINGLE LAYER COATING WITH EDGE COVERING PROPERTIES”, filed on June 7, 2024, the entire disclosure of which is incorporated by reference in its entirety. FIELD

[0002] The present disclosure relates to a single layer coating composition comprising a rheology modifier with edge protection that maintains glossiness and smoothness after curing. BACKGROUND

[0003] Coating compositions can be applied to a variety of substrates. However, when coating compositions are applied to substrates with sharp edges, the applied coating may pull away from the edge during the curing process. This may leave an exposed area of the substrate. When the substrate is metal, such exposed areas can lead to accelerated corrosion.

[0004] To prevent pull away, and the resulting edge exposure, coatings are often applied in a two-layer stackup, where the first layer comprises a primer coating, and the second layer comprises a top / finishing layer. The primer layer is applied to the bare substrate and adheres well to the edges, however, the applied primer layer results in a high surface roughness and unpleasant appearance. The top / finishing layer is therefore applied on top of the primer layer, resulting in a two-layer stackup, where the top layer has a low surface roughness and is acceptably smooth / glossy in appearance. Often, the primer layer and the top / finishing layer are applied in separate application processes (e.g., requiring separate curing / baking steps).

[0005] What is needed is a single layer coating that has both edge protection and maintains coating appearance such as gloss and smoothness. SUMMARY

[0006] The present disclosure provides a coating composition including a binder resin, a crosslinker, one or more fillers, and an acid functional urethane rheology modifier.

[0007] The present disclosure also provides a coating composition including a binder resin and an acid functional urethane rheology modifier. The binder resin includes at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin. The rheology modifier is formed from the reaction of 12-hydroxy stearic acid and a polyisocyanate.

[0008] The present disclosure further provides a method of coating an article including mixing a binder resin, an acid functional urethane rheology modifier, and a filler to form a coating composition; and applying the coating composition onto a surface of the article. The binder resin includes at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin. The filler includes at least one of a pigment, a colorant, and an additive. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description taken in conjunction with the accompanying drawings. These above-mentioned and other features of the disclosure may be used in any combination or permutation.

[0010] FIG.1A illustrates a substrate with a corner coated by a known double-coat coating composition;

[0011] FIG.1B illustrates a substrate with a corner coated by a known single-coat coating composition; and

[0012] FIG.2 illustrates a substrate with a corner coated by the coating composition of the present disclosure.

[0013] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate the disclosure, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner. DETAILED DESCRIPTION

[0014] The present disclosure provides a single layer coating composition. The coating composition may be a powder coating composition.I. Definitions

[0015] For purposes of the following detailed description, it is to be understood that the disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term "about." For example, numerical ranges provided for weight percentages of components or amounts of components added should be construed as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0016] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

[0017] Whereas particular examples of this disclosure have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from what is defined in the appended claims.

[0018] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges from (and including) the recited minimum value of 1 to the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0019] The use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, the use of "or" means "and / or" unless specifically stated otherwise, even though "and / or" may be explicitly used in certain instances.

[0020] As used herein, the term “powder coating composition” refers to a coating composition embodied in solid particulate form as opposed to liquid form.

[0021] As used herein, the term “resin” may be used interchangeably with “polymer.” The term polymer refers to oligomers and homopolymers (e.g., prepared from a single monomer species), copolymers (e.g., prepared from at least two monomer species), terpolymers (e.g., prepared from at least three monomer species), and graft polymers.

[0022] “Insoluble in solvent” refers to a chemical compound or composition having a solubility in a solvent of less than 0.05 g / L at room temperature. II. Coating Composition

[0023] The coating composition of the present disclosure comprises a resin, a crosslinker, one or more fillers, and a rheology modifier. Additionally, the coating composition may comprise any combination of pigments, catalysts, adhesion promoters, and / or degassing agents. The combination of the foregoing components may result in a single-layer coating composition that, once applied, results in high edge performance while acceptably maintaining a smooth / glossy appearance. The coating composition may be in a variety of forms including liquid coatings, and particularly, “powder” coating compositions, described herein.

[0024] A. Polymeric Binder Resin

[0025] The coating compositions herein may comprise a binder or a film-forming resin. A “binder” refers to a constituent material that may hold all coating composition components together upon curing. The binder may comprise one or more film-forming resins that may be used to form the coating layer. As used herein, a “film-forming resin” refers to a resin that may form a self-supporting continuous film on at least a horizontal surface of a substrate upon removal or any diluents or carriers present in the composition and / or upon curing. The term “resin” is used here interchangeably with “polymer”. Film-forming resins may be incorporated into components of the coating compositions as a liquid or as a solid. In the case of coating compositions, the binder (or film former) may be a polymeric powder material comprising polymeric particles.

[0026] Suitable binder resins include (meth)acrylate (e.g., acrylic) resins, polyurethanes, polyesters, polyamides, polyethers, polysiloxanes, epoxy resins, vinyl resins, copolymers thereof, and combinations thereof. As used herein, "(meth)acrylate" and like terms refers both to theacrylate and the corresponding methacrylate. Further, the binder resins may have any of a variety of functional groups including, but not limited to, carboxylic acid groups, amine groups, epoxide groups, hydroxyl groups, thiol groups, carbamate groups, amide groups, urea groups, isocyanate groups (including blocked isocyanate groups), and combinations thereof. Examples of suitable polyester-based resins include Uralac P5504: an alcohol functional polyester resin commercially available through DSM. Examples of suitable acrylic resins include Almatex PD6300: a glycidyl methacrylate based poxy functional acrylic resin commercially available through Anderson Development Company. Examples of suitable epoxy resins include NPES-903: a medium molecular weight solid epoxy resin based on bisphenol A, commercially available from Nan Ya Plastics Corp. The coating compositions may comprise any number of binder resins, such as one binder resin, or two or more binder resins.

[0027] The coating composition used with the present disclosure may include any variety of thermosetting powder compositions. As used herein, the term “thermosetting” refers to compositions that “set” irreversibly upon curing or crosslinking, wherein polymer chains of polymeric components are joined together by covalent bonds. This property is usually associated with a cross-linking reaction of the composition constituents often induced, for example, by heat or radiation. Once cured, a thermosetting resin will not melt upon the application of heat and is insoluble in solvents. The coating compositions used with the present disclosure may also include thermoplastic powder compositions. As used herein, “thermoplastic” refers to compositions that include polymeric components that are not joined by covalent bonds and, thereby, can undergo liquid flow upon heating.

[0028] The coating composition may comprise an amount of binder resin from 50 wt. %, 60 wt. %, or 65 wt. % to 70 wt. %, 75 wt. %, or 90 wt. %, or any range using any of the foregoing values as endpoints, such as 50 wt. % to 90 wt. %, 60 wt. % to 75 wt. %, or 65 wt. % to 70 wt. %, based on the total weight of the coating composition

[0029] The binder resin of the coating composition may be a polyester resin, an epoxy resin, a polyester epoxy hybrid resin, or acrylic resin, as described in further detail herein.

[0030] i. Polyester-based Resin

[0031] In some cases, the binder resin may comprise a polyester-based resin. The polyester-based resin serves as the primary binder, composed of ester linkages, allowing for excellent mechanical strength and adhesion to the substrate. The polyester may be an acidfunctional or hydroxyl functional polyester resin. For instance, polyesters may comprise the reaction product of a polyacid and a polyol.

[0032] The polyester resin may be generated by a polycondensation reaction between dicarboxylic acids and diols resulting in ester linkages within the polymer chain. The reaction between the carboxyl (-COOH) groups of the dicarboxylic acid and the hydroxyl (-OH) groups of the diol form the ester (-COO-) linkages from the backbone of the polymer chain.

[0033] Suitable dicarboxylic acids may include phthalic acid, isophthalic acid, terephthalic acid, adipic acid, and maleic acid.

[0034] Suitable diols, also known as glycols, may include ethylene glycol, propylene glycol, butanediol, neopentyl glycol, diethylene glycol, and 1,6-hexanediol (commercially available from BASF, CAS number 629-11-8).

[0035] Examples of suitable carboxyl-functional polyester formulations include Rucote 9010, a carboxyl functional polyester resin commercially available from Stepan (product code 7975), Sun Sparkle SP-6400, Crylcoat 1540 manufactured by Allnex, Crylcoat 2437, Crylcoat 4488, and Reafree 4703. Suitable hydroxyl-functional polyester may include Uralac P 5525 manufactured by Convestro, Rucote 117, Crylcoat 2890.

[0036] The polyester resin may have a glass transition temperature (Tg) of 50°C, 60°C, 70°C to 80°C, 90°C, or 100°C, or any range using any of the foregoing values as endpoints, such as 50°C to 100°C, 60°C to 90°C, or 70°C to 80°C, as determined according to ASTM D7028 (2015).

[0037] The polyester resin may have an acid value of 25, 27, or 29 to 31, 33, or 35 or any range using any of the foregoing as endpoints, such as 25 to 35, 27 to 33, or 29 to 31, as determined according to ASTM D7253 (2022).

[0038] The polyester resin may have a hydroxyl value of 20, 50, or 100 to 150, 200, to 300, or any range using any two of the foregoing values as endpoints, such as 20 to 300, 50 to 200, or 100 to 150, as determined according to ASTM D4274 (2022).

[0039] ii. Epoxy Resin

[0040] The binder resin may be an epoxy-based resin. Epoxy resins are thermosetting polymers characterized by the presence of epoxy groups in their molecular structure. Epoxy resins comprise three-membered cyclic ethers (oxirane rings or epoxy functional groups), typically derived from epichlorohydrin and an hydroxyl (OH) containing compound, such asbisphenol-A (BPA), resorcinol, hydroquinone, 4,4′-dihydroxydiphenyl methane (or bisphenol F), 4,4′-dihydroxy-3,3′-dimethyldiphenyl methane, 4,4′-dihydroxydiphenyl dimethyl methane (or bisphenol A), 4,4′-dihydroxydiphenyl methyl methane, 4,4′-dihydroxydiphenyl cyclohexane, 4,4′-dihydroxy-3,3′-dimethyldiphenyl propane, 4,4′-dihydroxydiphenyl sulfone, tris (4- hydroxyphynyl)methane, and combinations thereof. The backbone of the epoxy resin consists of repeating units containing epoxy groups (Rn-C-O-C-Rn), where R represents a variety of organic substituents and n represents the number of R groups and is any integer greater than 1.

[0041] The synthesis of epoxy resins involves the reaction between epichlorohydrin and BPA in the presence of a base catalyst, such as sodium hydroxide. This reaction results in the formation of a linear chain polymer with pendant epoxy groups along the backbone. Additional curing agents or hardeners, such as amines or acid anhydrides, can be added to the epoxy resin to facilitate crosslinking and cure the material into a thermoset polymer. Examples of suitable diepoxy formulations include KD-242G (manufactured by Kukdo Chemical Co, Ltd., CAS number 25036-25-3), Epon 2004, Epon 2002, Epon 1001F, NPES-903.

[0042] The softening point of a resin refers to the temperature at which the resin begins to soften and lose its rigidity. The softening point may indicate when the resin transitions from a solid to a more pliable or viscous state. The epoxy resin may have a softening point of 80, 90, 100 to 105, 110, or 120, or any range using any of the foregoing values as endpoints, such as 80 to 120, 90 to 110, or 100 to 105, as determined according to ASTM D3104 (2018).

[0043] The epoxy resin may have an epoxy equivalent weight (EEW) of 500g, 600g, or 700g to 800g, 900g, or 1000g, or any range using any two of the foregoing values, such as 500g to 1000g, 600g to 900g, or 700g to 800g, as determined by ASTM D1652 (2019).

[0044] iii. Polyester Epoxy Hybrid Resin

[0045] The binder resin may be a polyester epoxy hybrid resin made from combining polyester resin and epoxy resin into a singular polymer chain. The hybrid resin may exhibit a combination of properties from each of the polyester and epoxy resins described previously. The polyester hybrid resin may comprise any combination of the foregoing compounds as described in Sections i and ii above.

[0046] The binder resin may comprises from 10 wt.% to 80 wt.% of polyester resin and from 10 wt. % to 80 wt. % of epoxy resin, such as from 35 wt.% to 65 wt.% of polyester resin to35 wt. % to 65 wt. % of epoxy resin, and more particularly, 45 wt.% to 55 wt.% of polyester resin to 45 wt. % to 55 wt. % of epoxy resin.

[0047] The polyester epoxy hybrid resin may have an epoxy equivalent weight (EEW) of 500g, 600g, or 700g to 800g, 900g, or 1000g, or any range using any two of the foregoing values, such as 500g to 1000g, 600g to 900g, or 700g to 800g, as determined by ASTM D1652 (2019).

[0048] iv. Acrylic Resin

[0049] Acrylic resins are thermoplastic polymers derived from the polymerization of acrylic monomers, such as methyl methacrylate (MMA), acrylic acid, ethyl acrylate, butyl acrylate, and acrylic acid. The acrylic monomers may be polymerized into long chains of repeating units to form the acrylic resin.

[0050] The acrylic resin may have a glass transition temperature (Tg) of 50°C, 60°C, or 70°C to 80°C, 90°C, or 100°C, or any range using any of the foregoing values as endpoints, such as 50°C to 100°C, 60°C to 90°C, or 70°C to 80°C, as determined according to ASTM D7028 (2015).

[0051] The acrylic resin may have an epoxy equivalent weight (EEW) of 500g, 600g, or 700g to 800g, 900g, or 1000g, or any range using any two of the foregoing values, such as 500g to 1000g, 600g to 900g, or 700g to 800g, as determined by ASTM D1652 (2019).

[0052] Suitable acrylic resins may include Almatex PD-7610 and Alnatex PD-3402, both manufactured by Anderson Development.

[0053] B. Crosslinker

[0054] The coating compositions of the present disclosure may comprise a one or more crosslinkers in one or multiple components that may be selected from any of the crosslinkers known in the art to react with the functionality of one or more binder resins used in the coating composition. As used herein, the term "crosslinker" refers to a molecule comprising two or more functional groups that are reactive with other functional groups and that is capable of linking two or more monomers or polymers through chemical bonds. Alternatively, the binder resins that form the binder of the coating composition may have functional groups that are reactive with themselves; in this manner, such resins are self-crosslinking.

[0055] Suitable crosslinkers include phenolic resins, amino resins, epoxy resins, triglycidyl isocyanurate, beta-hydroxy (alkyl) amides, alkylated carbamates, (meth)acrylates,isocyanates, polyisocyanates, blocked isocyanates, dicyandiamide, hydroxylalkylurea, polyacids, anhydrides, organometallic acid-functional materials, polyamines, polyamides, aminoplasts, carbodiimides, oxazolines, tetrakis(methoxymethyl)glycoluril, and combinations thereof. Examples of suitable crosslinkers include tri glycidyl isocyanurate (TGIC) manufactured by Huangshan Linlu Coatings Materials, CAS number 2451-62-9; a dicyandiamide crosslinker, such as Dyhard manufactured by Alzchem LLC, CAS number 461-58-5; Dodecanedioic Acid manufactured by Evonik Industries, CAS number 692-23-2; and Primid XL-552, a hydroxyalkylamide crosslinker manufactured by EMS-American Grilon (CAS number 119-53- 9), and the like.

[0056] The crosslinker may comprise from as little as 1 wt. %, 2 wt. %, 3 wt. %, or 5 wt. % to as much as 8 wt. %, 10 wt. %, 20 wt. %, or 30 wt. %, or any range using any of the foregoing values as endpoints, such as 1 wt. % to 30 wt. %, 2 wt. % to 20 wt. %, 3 wt. % to 10 wt. %, or 5 wt. % to 8 wt. %.

[0057] C. Rheology Modifier

[0058] The coating composition may comprise one or more rheology modifiers. The rheology modifier(s) may be used to control the viscosity and flow properties of the coating composition during the application and / or curing processes. Specifically, rheology modifiers may be used to ensure smooth spreading of the applied coating, uniform coverage, and prevent the applied coating from sagging and / or dripping. More particularly, the rheology modifier may be used to control the rheology and / or viscosity of the applied composition such that the desired edge coverage of the underlaying substrate is achieved, while also resulting in an acceptably smooth surface of the cured composition.

[0059] The rheology modifier may comprise a polymeric material which includes an alternating structure of polar and non-polar segments, alternating segments of linear aliphatic carbons and cyclic carbonyls. The alternating structure of the polar and the non-polar segments control the rheology of the composition during the curing window. Such control allows for covering of sharp edges of the underlying substrate while attaining a sufficient level of surface leveling to maintain a smooth appearance. It is theorized that the polar segments, which may comprise an acidic / acid functional group, coordinates with the particles of the coating, restricting the bulk flow of the coating and allowing for acceptable edge hold on the underlying substrate. It is further theorized that the non-polar segments are surface active, lowering the surface tensionof the coating, which results in surface leveling upon curing. It has been surprisingly found that inclusion of the rheology modifier including the alternating polar and non-polar segments in the coating composition achieves the desired edge coverage while simultaneously attaining a satisfactory level of surface smoothness, as will be described in further detail herein.

[0060] Examples of suitable rheology modifiers include surfactant-based rheology modifiers, acid-functional rheology modifiers, and particle-coordinating rheology modifiers, where each include the polar and non-polar segments as described previously. Specific instances of rheology modifiers include acid functional urethane rheology modifiers. Examples of acid functional rheology modifiers include the reaction product formed from the reaction of a hydroxy functional acid, such as 12-hydroxy stearic acid (12 HSA) such as 12 HSA available from AZEVEDO INDUSTRY CAS number 106-14-9, and a polyisocyanate, such as Desmodur N3790 available from Covestro, Desmodur N33300 available from Covestro, and Vestanat T1890 / 100 available from Evonik Industries, CAS number 53880-05-0. The reaction may take place in the presence of a catalyst, such as dibutyl tin dilaurate available from Evonik Industries, stannous octoate available from TIB Chemicals, or combinations thereof; and / or a solvent, such as butyl acetate (CAS number: 123-86-4).1,6-hexanediol available from BASF, methyl isobutyl ketone (MIBK), isostearyl alcohol available from Ambeed, or combinations thereof. The reaction mechanism by which the acid functional urethane rheology modifier is formed is shown in Mechanism I, below. OH O

[0061] The mole ratio of 12 HSA to polyisocyanate may be 1:0.5, 0.5:1.0, 1.0:0.75, 0.95:1.0, or 1.0:0.95.

[0062] Alternatively, the rheology modifier may be formed in a ring opening polymerization by the reaction of a hydroxy functional acid, such as 12 HSA, with a cyclic monomer, such as an ester monomer including ε-caprolacetone available from BASF, and a catalyst, such as dibutyl tin dilaurate available from Evonik Industries, stannous octoate available from TIB Chemicals, or combinations thereof. The reaction may take place in the presence of a solvent, such as butyl acetate (CAS number: 123-86-4).1,6-hexanediol available from BASF, methyl isobutyl ketone (MIBK), isostearyl alcohol available from Ambeed, or combinations thereof.

[0063] A suitable reaction mechanism by which the rheology modifier may be formed from 12 HAS, ε-caprolacetone, stannous octoate, and MIBK using a ring opening polymerization is shown in Mechanism II, below. OOOOHMechanism II

[0064] A hydroxyl group on 12-HSA acts as the initiator. In the presence of a catalyst, such as stannous octoate, the ring of the monomer is activated and undergoes nucleophilic attack by the –OH group of 12-HSA. This opens the ring, forming a new linkage. Additional ε- caprolactone monomers are opened and added to the growing chain, forming chains with a 12- HSA group at one end (Intermediate A).

[0065] The resulting Intermediated A polymer further reacts with isocyanate group from Desmodur N 3790 in the presence of a catalyst such as Dibutyltin dilaurate to the final product which is the rheology modifier of the present disclosure.

[0066] The coating composition may comprise an amount of rheology modifier from 1 wt. %, 2 wt. %, or 3 wt. % to 4 wt. %, 5 wt. %, or 6 wt. %, or any range using any two of the foregoing values as endpoints, such as 1 wt. % to 6 wt. %, 2 wt. % to 5 wt. %, and 3 wt. to 4 wt.%., as based on the total weight of the coating composition.

[0067] D. Filler

[0068] The coating composition may further comprise one or more fillers. The filler may comprise an inorganic compound, an organic compound, a colorant, a pigment, an additive, or any other suitable filler material.

[0069] The filler may be present in the coating composition in an amounts from 1 wt. %, 10 wt. %, 15 wt. %, or 20 wt. % to 25 wt. %, 30 wt. %, 35 wt. %, or 50 wt. % or any range using any two of the foregoing values as endpoints, such as 1 to 50 wt. %, 10 to 35 wt. %, 15 wt. % to 30 wt. %, or 20 wt. % to 25 wt. %, based on the total weight of the coating composition.

[0070] i. Inorganic Compounds

[0071] The filler(s) may comprise one or more inorganic compounds. Suitable fillers may include finely divided minerals such as barium sulfate, such as VBF Micro 1 manufactured by Kish Company (CAS Number:7727-43-7), silica, including fumed silica and colloidal silica, alumina, colloidal alumina, fumed aluminum oxide, such as Aeroxide Alu C manufactured by Evonik (CAS number 1344-28-1), titanium dioxide, zirconia, colloidal zirconia, clay, mica, dolomite, talc, magnesium carbonate, calcium carbonate, calcium sulfate, calcium silicate, and / or calcium metasilicate.

[0072] ii. Organic Compounds

[0073] The filler(s) may comprise one or more organic compounds. Suitable fillers may include finely divided minerals such as cellulose and lignin.

[0074] iii. Pigments / Colorants

[0075] The filler may comprise pigments (organic or inorganic), dyes, colorants, and tints, such as those used in the paint industry and / or listed in the Dry Color Manufacturers Association (DCMA), as well as special effect compositions. A colorant may include a finely divided solid powder that is insoluble, but wettable, under the conditions of use. A colorant may be organic or inorganic and may be agglomerated or non-agglomerated. Colorants may be incorporated into the coatings by use of a grind vehicle, such as an acrylic grind vehicle, the use of which will be familiar to one skilled in the art.

[0076] Suitable pigments and colorants may include, but are not limited to, carbazole dioxazine crude pigment, iron oxide, bismuth vanadate, phthalocyanine, sodium alumino sulfosilicate, azo, monoazo, diazo, naphthol AS, benzimidazolone, isoindoline and polycyclic phthalocyanine, quinacridone, perylene, perinone, diketopyrrolo pyrrole, thioindigo, anthraquinone, indanthrone, anthrapyrimidine, flavanthrone, pyranthrone, anthanthrone, dioxazine, triarylcarbonium, quinophthalone pigments, diketo pyrrolo pyrrole red ("DPPBO red"), titanium dioxide, carbon black such as Printex G available from Orion Engineered Carbons (CAS number 1333-86-4), and mixtures thereof.

[0077] The pigment and / or colorant may be present in the coating composition in an amount from 0.1 wt. %, 1 wt. %, or 5 wt. % to 10 wt. %, 20 wt. %, or 40 wt. %, or any range using any two of the foregoing values as endpoints, such as 0.1 wt. % to 40 wt. %, 1 wt. % to 20 wt. %, or 5 wt. % to 10 wt. %, based on the total weight of the coating composition.

[0078] iv. Additives

[0079] The coating composition may further optionally comprise one or more additives. Such additives may include solvents, flow control agents, flow restricting agents, dry flow agents, antioxidants, optical brighteners, adhesion promoters, extenders, surface control agents, waxes, catalysts, reaction inhibitors, corrosion-inhibitors, conductivity enhancers, degassing agents, and combinations comprising at least one of the foregoing additives, and the like.

[0080] Any of the foregoing additives may be present in the coating composition in an amount as little as 0.01 wt.%, 0.05 wt. %, or 0.07 wt. %, to as high as 1.00 wt. %, 2.00 wt. % or 3.00 wt. %, or any range using any two of the foregoing values as endpoints, such as 0.01 wt. %to 3.00 wt. %, 0.05 wt. % to 2.00 wt. %, and 0.07 wt. to 1.00 wt. %, as based on the total weight of the coating composition.

[0081] The coating composition may comprise a solvent. Suitable solvents may comprise butyl acetate (CAS number 123-86-4), 1,6-hexanediol (available from BASF, CAS number 629-11-8), methyl isobutyl ketone (CAS number 108-10-1), and isostearyl alcohol (available from Ambeed, CAS number 27458-93-1).

[0082] The coating composition may comprise a catalyst. The catalyst initiates and / or accelerates the curing process of the coating. Here, the catalyst facilitates the cross-linking reaction between the resin molecules, leading to the formation of a durable, chemically bonded coating during the curing process. Examples of suitable catalysts include amine catalyst (dimethyl laurylamine), onium salts (tertbutyl phosphonium bromide, tertabutyl ammonium chloride), imidazoles (2-methyl imidazole, propyl imidazole), metal complexes (dibutyl tin dilaurate and tin(II) 2-ethylhexanoate). Specifically, the catalyst may comprise Curaid DMLA-P, a dimethyl lauryl type amine catalyst, commercially available from Sovereign Technologies (in 65% CAS Number 112-18-5, in 35% CAS Number 112926-00-8), Dyhard MI-FF (2-methyl imidazole), Dyhard 2PI (2-propyl imidazole), Escat BT-71 (dibutyl tin dilaurate available from Evonik Industries, CAS number 77-58-5), and stannous octoate (tin(II) 2-ethylhexanoate available from TIB CHEMICALS, CAS number 301-10-0).

[0083] The coating composition may further optionally comprise flow control agents, sometimes called leveling agents, which are useful to promote the formation of a continuous and even coating. Suitable flow control agents include polyacrylic esters, non-ionic fluorinated alkyl ester surfactants, non-ionic alkylarylpolyether alcohols, silicones, and the like, and combinations comprising at least one of the foregoing flow control agents. Flow control agents are generally liquids that have been converted to powder form by absorption onto silica-type materials. Examples of suitable flow control agents include 2-propenoic acid; ethyl ester polymer acrylic resin, available under the tradename RESIFLOW® P-67 by Estron Chemical Inc.; 2-hydroxy- 1,2-diphenylethanone which is a crystalline solid that is believed to keep the molten coating open for a suitable time to allow outgassing to occur prior to the formation of the hard-set film, sold under the tradename Benzoin by DSM, Inc. Resiflow PL200 available from Estron Chemicals (CAS Number 112926-00-8); and a low viscosity acrylic polymer adsorbed onto silicacommercially available through Estron Chemical. The coating composition may also include a dry flow agent such as fumed silica.

[0084] The coating composition may comprise an adhesion promoter, also known as a coupling or bonding agent. The adhesion promoter may modify the interface between the substrate and the coating, improving the bond strength and durability of the coating system. Suitable adhesion promoters may include silane coupling agents, titanate coupling agents, surfactant-based adhesion promotors, phosphate-based compounds, epoxy resins, polyester resins, and acrylic resins, such as gamma-aminopropyltriethoxysilane, methacryloxypropyltrimethoxysilane (MPS), epoxy functional silanes, tetraalkoxy titanates, zinc phosphate, iron phosphate compounds, glycidyl methacrylate (GMA), hydroxy functional polyester resins, carboxyl functional polyester resins, hydroxyl functional acrylic resins, methacrylate functional acrylic resins, and combinations thereof.

[0085] The coating composition may further comprise a degassing agent, also known as a defoamer or antifoaming agent. The degassing agent is a chemical additive used to control or eliminate foam formation during the manufacturing, processing, or application of various substances, such as liquids or coatings. Foam formation can occur due to the presence of entrapped air or gas bubbles, agitation, chemical reactions, or surfactant activity. Degassing agents work by breaking down or preventing the formation of foam, thus improving processing efficiency, product quality, and performance. Suitable examples of degassing agents include silicone-based defoamers, polymer-based defoamers, mineral-based defoamers, and surfactant- based defoamers, such as polydimethylsiloxane (PDMS), silicone surfactants, polyacrylate-based defoamers, mineral oil, paraffin wax emulsions, silica nanoparticles, colloidal silica dispersions, non-ionic surfactants, fatty acid derivatives, or combinations thereof. Specific examples include Benzoin, commercially available from Huangshan Linlu Coatings Materials (CAS number 119- 53-9).

[0086] Any particular additive or any combination of additives may be present in the coating composition in an amount from 0.1 wt. %, 1 wt. %, or 5 wt. % to 7 wt. %, 9 wt. %, or 11 wt. %, or any range using any two of the foregoing values as endpoints, such as 0.1 wt. % to 11 wt. %, 1 wt. % to 9 wt. %, or 5 wt. % to 7 wt. %, based on the total weight of the coating composition.

[0087] III. Properties of the Coating Composition

[0088] Once applied and cured, the resulting coating composition may exhibit desirable physical performance, as will be described in further detail herein. Specifically, the applied coating may exhibit a relative low plate flow (e.g., at or below 70 mm) and an acceptably smooth finish once cured (e.g., at or above a PCI value of 7).

[0089] A. Particle Size

[0090] After formulation, the coating composition may be ground into particles. The powder particles may have a mean average particle size (D50) of 25 µm, 30 µm, or 35 µm to 40 µm, 45 µm, or 50 µm, or any range using any of the foregoing values as endpoints, such as 25 µm to 50 µm, 30 µm to 45 µm, and 35 µm to 40 µm, as determined by ASTM D5851 (section 8.3, laser scattering dry sample). The coating composition may be ground using an Air Classifying Mill (ACM) and then passed through a mesh sieve.

[0091] B. Plate Flow

[0092] Plate flow describes how a coating composition moves on a vertical or near- vertical surface of a substrate when applied and during curing. Plate flow occurs due to the influence of gravity on the coating composition, causing the coating composition to flow downward under its own weight.

[0093] The plate flow of the coating composition may be measured according to ASTM D4242 (2017).

[0094] The coating composition of the present disclosure may have a plate flow of 40 mm, 45 mm, 46 mm, 47 mm, or 48 mm to 50 mm, 55 mm, 60 mm, 65 mm, or 70 mm, any range using any of the foregoing values as endpoints, such as 40 mm to 70 mm, 45 mm to 65 mm, 46 mm to 60 mm, or 47 mm to 55 mm, or 48 mm to 50 mm, at a curing temperature specified below, as determined according to ASTM D4242 at the curing temperatures described below.

[0095] Here, the low plate flow of the applied coating composition, such as at or 50 mm or less, results in a coating composition with enhanced edge coverage. Specifically, the applied coating may resist sagging and / or dripping, while also spreading smoothly and uniformly over the underlying substate, and particularly, at the edges of the substrate.

[0096]

[0097] IV. Application and Curing of the Coating Composition

[0098] The coating composition may be applied and cured on a variety of substrates to form a cured coating on the substrates. Suitable substrates may be metallic or non-metallic. Metallic substrates may include, but are not limited to, tin, steel, cold rolled steel, hot rolled steel, steel coated with zinc metal, zinc compounds, zinc alloys, electrogalvanized steel, hot- dipped galvanized steel, galvanealed steel, galvalume, steel plated with zinc alloy, stainless steel, zinc-aluminum-magnesium alloy coated steel, zinc-aluminum alloys, aluminum, aluminum alloys, aluminum plated steel, aluminum alloy plated steel, steel coated with a zinc-aluminum alloy, magnesium, magnesium alloys, nickel, nickel plating, bronze, tinplate, clad, titanium, brass, copper, silver, gold, 3-D printed metals, cast or forged metals and alloys, or combinations thereof.

[0099] Non-metallic substrates may include polymeric, plastic, polyester, polyolefin, polyamide, cellulosic, polystyrene, polyacrylic, poly(ethylene naphthalate), polypropylene, polyethylene, nylon, EVOH, polylactic acid, other “green” polymeric substrates, poly(ethyleneterephthalate) (PET), polycarbonate, engineering polymers such as poly(etheretherketone) (PEEK), polycarbonate acrylobutadiene styrene (PC / ABS), polyamide, wood, veneer, wood composite, particle board, medium density fiberboard, cement, stone, glass, paper, cardboard, textiles, leather both synthetic and natural, composite substrates such as fiberglass composites or carbon fiber composites, 3-D printed polymers and composites, and the like.

[0100] A. Application and Curing

[0101] i. Electrostatic Powder Spraying

[0102] The coating composition may be applied using electrostatic powder spraying. Electrostatic spraying may include the coating composition being applied in a powder recovery booth to an electrically conductive substrate, where an electrical charge has been applied to the powder particles therefore attracting the charged powder particles to the surfaces of the substrate. The electrically conductive substrate can be preheated prior to powder application (e.g., to increase the bonding of the coating particles to the surface of the substrate) and / or post-baked after the application of the powder (e.g., to initiate the reaction(s) necessary to form a polymeric coating on the substrate) to cure the coating composition.

[0103] The coating composition may be cured by post-baking at a temperature from 100oC, 150oC, or 190oC to 210oC, 230oC, or 250oC, or any range using any two of the foregoing values as endpoints, such as 100oC to 250oC, 150oC to 230oC, or 190oC to 210oC.

[0104] The coating composition may be cured for an amount of time from 1 min., 5 min., 10 min., or 20 min. to 30 min., 1 hour, 2 hours, or 3 hours, or any range using any of the foregoing values as endpoints, such as 1 min to 3 hours, 5 min. to 2 hours, 10 min. to 1 hour, or 20 min to 30 min.

[0105] During electrostatic spraying, the particles of coating composition are sprayed in a powdered state. An electrostatic gun may spray the charged powdered coating composition onto the substrate. The electrostatic gun may have a round spray nozzle / tip or a flat spray nozzle / tip. The electrostatic spray gun may spray the coating mixture at a variety of pressures, which may be adjusted to achieve a desired coating finish and / or effect. The coating mixture may be sprayed at 1 psig or greater, 5 psig or greater, 20 psig or greater, 25 psig or greater, or 30 psig or greater or 40 psig or less, 50 psig or less, 60 psig or less, or any range using any two of the foregoing values as endpoints, such as 1 psig to 60 psig, 5 psig to 50 psig, 20 psig to 40 psig, or 25 psig to 30 psig.

[0106] The electrostatic gun may comprise at least one electrode and a high-voltage generator. The high-voltage generator may generate a negative polarity to be applied to the electrode during application of the coating composition. The high-voltage generator can generate a negative polarity voltage of 0 KV or greater, 1 KV or greater, 10 KV or greater, 20 KV or greater, 30 KV or greater, 40 KV or greater, or 50 KV or less, 60 KV or less, 70 KV or less, 80 KV or less, 90 KV of less, 100 KV or less, or any range using any two of the foregoing values as endpoints, such as 0 KV to 100 KV, 1 KV to 90 KV, 10 KV to 80 KV, 20 KV to 50 KV, or 30 KV to 40 KV.

[0107] Excess powder particles that do not adhere during the spraying may be collected in a recovery booth and recycled using processing equipment. The powder booth equipment and / or the curing oven physical dimensions may also impose size limitations on the substrate (e.g., limited only to a small enough size to fit in the equipment) which often also limits the powder application only to disassembled individual parts (e.g., not being able to be applied to fully constructed components). Finally, in the case where a second layer of a coating is required, the substrate may pass through substantially the same coating process for a second time.

[0108] ii. Thermal Spraying

[0109] The coating composition may be applied via thermal spraying. To thermal spray the coating composition onto a substrate, the coating composition may be heated to an application temperature which at least partially melts / softens the powder particles in the presence of a carrier gas (e.g., air, inert gas, etc.). The coating composition may be heated to an application temperature from 100oC, 125oC, or 150oC to 175oC, 200oC, or 235oC, or any range using any two of the foregoing values as endpoints, such as 100oC to 225oC, 125oC to 200oC, or 150oC, or 175oC.

[0110] In the case of thermoset coatings, the pre-heating may initiate the chemical reaction(s) necessary (e.g., crosslinking, partial / full curing, etc.) to form the coating once applied to the substrate. The melted / softened powder particles are accelerated with the gas stream and deposited onto the substrate in a splattering pattern. The resulting coating cures on the substrate which may, but not necessarily, be accomplished in a post baking process (e.g., as based upon the curing requirements of the coating).

[0111] iii. Fluidized Bed Immersion

[0112] The coating composition may be applied to a substrate via fluidized bed immersion. A fluidized bed is created by blowing air or another gas through a bed of particles of the coating composition. The gas flow causes the coating composition to become suspended within the bed, resembling a fluid-like state. This fluidization allows the particles to behave like a liquid, enabling efficient coating of the substrate.

[0113] The substrate may be heated to allow the coating composition to flow evenly. The heated substrate may be then immersed directly into the fluidized bed containing the coating composition. As the substrate enters the bed, the fluidized coating composition particles adhere to its surface, forming a uniform coating layer. The heat from the substrate causes the coating particles to melt and fuse together, forming a continuous film over the surface. The thickness of the coating can be controlled by adjusting parameters such as immersion time, substrate temperature, and the particle size of the coating composition.

[0114] B. Single Layer Application

[0115] The coating composition can be applied to a substrate to form a monocoat. As used herein, a “monocoat” refers to a single layer coating system that is free of additional coating layers. Thus, the coating composition can be applied directly to a substrate and cured to form asingle layer coating, i.e., a monocoat. The coating composition may include additional components to provide other desirable properties, such as adhesion promoters.

[0116] V. Properties of the Cured Coating

[0117] Substrates coated according to the present disclosure may have one or more improved properties and may address one or more issues known in the coating industry. The improved properties may be observed in comparison to other, previously known coating compositions.

[0118] A. Gloss

[0119] Gloss measurements of a cured coating may be used to evaluate the appearance and finish of the coating. Gloss refers to the sheen or shine of a surface and plays a role in the aesthetics of coatings, as well as in the functionality and performance of the coating. Gloss measurements may be taken using a gloss meter, also known as a glossmeter. These devices are designed to quantify the specular reflection of light off a surface. The gloss of a coating may be taken at different angles, such as at 20° and 60° to the surface of the substrate coated with the cured coating.

[0120] The glossiness of the cured coating may be measured according to the following method. The coating composition is applied to 4x12 CRS panels with B1000 P99X pretreatment and cured at a specified cure temperature and time such that the cured coating has an approximate dry film thickness of 76.2 µm. Using a BYK TriGloss (Serial No.1103923) three measurements are taken across the length of the panel, and the gloss was averaged over the three measurements. Dry film thickness was measured according to ASTM D1005 (2022).

[0121] The cured coating may have a gloss value at 20oof 75, 78, 79, or 80 to 81, 82, 84, or 85 or any range using any of the foregoing values as endpoints, such as 75 to 85, 79 to 84, or 79 to 82, as determined by the method described above.

[0122] The cured coating may have a gloss value at 60oof 85, 90, or 92 to 93, 94, or 95, or any range using any of the foregoing values as endpoints, such as 85 to 95, 90 to 94, or 92 to 94, as determined by the method described above.

[0123] B. Smoothness

[0124] The smoothness of a cured coating may refer to the surface texture and appearance of the coated substrate. A smooth finish may be desired to enhance aesthetics of thesubstrate and contribute to the performance of the coating. A smoothness standard panel rating, such as the standard panels determined by Power Coating Institute (PCI) or ACT Test Panel Technologies, may be used to determine the smoothness of the cured coating. The panels may be rated 1 to 10 based on a comparison to the standard panels.

[0125] As described with reference to FIG.1, known coatings 100 are often applied to a substrate 10 in a two-layer stackup, where the first layer comprises a primer coating 102, and the second layer comprises a top / finishing layer 104, as shown in FIG.1A. Applied primer layer 102 may cause high surface roughness 15. Top / finishing layer 104 is therefore applied on top of primer layer 102, resulting in a two-layer stackup 200, where top layer 104 has a low surface roughness and is acceptably smooth / glossy in appearance. Primer layer 102 and top / finishing layer 104 may be applied in separate application processes, requiring separate curing / baking steps.

[0126] Conversely, as shown in FIG.2, the coating composition of the present disclosure 300 comprises a single coat that evenly coats the surface of the substrate 10 with high surface smoothness 16 without application of a primer.

[0127] Smoothness of the cured coating of the present disclosure may be evaluated using the following method. The coating composition is applied to 4x12 CRS panels with B1000 P99X pretreatment and cured at a specified cure temperature and time such that the cured coating has an approximate dry film thickness of 76.2 µm. Dry film thickness was measured according to ASTM D3451, section 32.8.2 (2017). A coated orange peel is compared to ACT powder smoothness standards (Item No.22163) and assigned the rating most similar to a non-coated orange peel standard. Three different reviewers assign the comparative ACT standard smoothness rating to the example panels, and ratings are averaged across the three reviewers.

[0128] The cured coating may have a smoothness / PCI rating from 7, 7.5, or 8 to 8.5, 9, or 9.5, or any range using any of the foregoing values as endpoints, such as 7 to 9.5, 7.5 to 9, or 8 to 8.5, as determined according to the method described above.

[0129] C. Edge Corrosion

[0130] Edge corrosion refers to the localized degradation of a coating at the edges or boundaries of coated substrate, particularly where the coating meets a corner, an exposed substrate, and / or another material. This phenomenon is commonly observed in metal structuresor components that have been coated for corrosion protection. Edge corrosion can compromise the integrity of the coating system and lead to accelerated corrosion of the underlying substrate.

[0131] Known single-coat coating compositions 200 are shown in FIG.1B. The single- coat coating composition 200 may pull away from the corner of the substrate leaving an exposed corner 12. The coating composition of the present disclosure 300, shown in FIG.2, evenly coats the surface of substrate 10 and has excellent edge coverage 14 at the corner of substrate 10.

[0132] The percentage of corrosion of the cured coating of the present disclosure at the edges of the substrate may be tested according to the following method. The cured coating is applied to non-pretreated cold rolled steel parts containing laser cut edges. After curing at the specified time and temperatures, parts are placed in SAE J2334 cyclic corrosion testing and run for 7 cycles (7 days). The part's edges are divided into 0.5 inch sections, and the number of edge sections containing rust are counted after each part is removed from accelerated corrosion testing. The results are reported as the percent of the total edges of the part which contain rust. For each coating 3 parts were prepared, and the results were averaged.

[0133] The cured coating may have a percent corrosion on edge from 0 %, 1 %, or 5 % to 10 %, 15 %, or 20 % or any range using any of the foregoing values as endpoints, such as 0 % to 20 %, 1 % to 15 %, 5 % or 10 %, based on the percent of the total edges of the part which contain rust, as determined according to the method above.

[0134] D. TRICOR Distinctiveness of Image (DOI) / Haze

[0135] Distinctiveness of Image (DOI) is a measure used to quantify the clarity (or haziness) and sharpness of reflections on the surface of a coating. In the context of coating compositions, DOI refers to the ability of a coating to produce clear, non-hazy, mirror-like reflections that accurately reflect the surrounding environment without distortion or waviness. Higher DOI values (e.g., closer to 100, 100 indicating a perfectly smooth and mirror-like surface) indicate a smoother and more mirror-like finish, with reflections appearing sharper and more distinct. Low DOI values indicate an unacceptably low level of surface smoothness or reflectiveness.

[0136] The DOI / haze of the cured coating of the present disclosure may be evaluated according to the following method. The coating composition is applied to 4x12 CRS panels with B1000 P99X pretreatment and cured at a specified cure temperature and time such that the cured coating has an approximate dry film thickness of 76.2 µm. Dry film thickness was measuredaccording to ASTM D1005 (2020). Using a TRICOR DOI / Haze Meter (Model 807A) three measurements are taken across the length of the panel, and the DOI is averaged over the three measurements, according to ASTM D5767 (2023).

[0137] The cured coating may have a DOI of 40, 45, or 50 to 55, 60, or 65, or any range using any of the foregoing values as endpoints, such as 40 to 65, 45 to 60, or 50 to 55, as determined according to the method above.

[0138] E. Surface roughness (R Value)

[0139] Surface roughness, or "R value," may refer to a surface roughness parameter obtained from a surface analysis technique such as profilometry. The R value relates to a calculation of paint smoothness developed by BYK, which is calculated using a BYK WaveScan.

[0140] The R value of the cured coating of the present disclosure may be evaluated according to the following method. The coating is applied to 4x12 CRS panels with B1000 P99X pretreatment and cured at a specified cure temperature and time such that the cured coating has an approximate dry film thickness of 76.2 µm. Dry film thickness was measured according to ASTM D3451, section 32.8.2 (2017). Using a BYK WaveScan (Model 4806) three measurements are taken across the length of the panel, and the R Value is averaged over the three measurements.

[0141] The cured coating may have an R value from 3, 6, or 7 to 8, 9, or 10, or any range using any of the foregoing values as endpoints, such as 3 to 10, 6 to 9, or 7 to 8, as determined according to the method above.

[0142] F. Film Thickness

[0143] Film thickness of the resulting coating may refer to the thickness of the applied and cured coating on a substrate. Sufficient film thickness, and particularly the film thickness at the edges of the underlying substrate, is used to protect the underlying substrate from corrosion, maintain the aesthetic of the coated article and maintain desirable cured coating performance, such as surface hardness. Referring to FIG.2, the coating composition of the present disclosure 300 may coat a substrate 10 and provide covered corners 14 and an even film thickness 18 along the entire surface of substrate 10.

[0144] The cured coating may have a film thickness of as little as 0.5 mil (.0127 mm), 1.0 mil (.0254 mm), or 2.0 mil (.0508 mm), to as high as 3.0 mil (.0762 mm), 5.0 mil (.1275mm), or 6.0 mil (.1525 mm), or any range using any of the foregoing values as endpoints, such as 0.5 mil to 6 mil, 1.0 mil to 5 mil, or 2.0 mil to 3.0 mil, as determined by ASTM D1005 (2020).

[0145] EXAMPLES

[0146] Aspects of the present disclosure are further illustrated by reference to the following examples. It will be apparent to those skilled in the art that many modifications, both to materials, and methods, may be practiced without departing from the scope of the disclosure. EXAMPLE 1: SYNTHESIS OF ACID URETHANE RHEOLOGY MODIFIERS

[0147] Rheology modifiers A-F were formulated according to the descriptions and Tables 1-6 below. The amount (wt. %) of each component listed in Tables 1-6 is based on the total weight of the rheology modifier.

[0148] Rheology Modifier A Table 1: Formulation of Rheology Modifier A Component Grams (g) Wt. %1DESMOD.2Dibutyl tin dilaurate is commercially available from Evonik Industries.312-Hydroxy Stearic acid is commercially available from AZEVEDO INDUSTRY.

[0149]

[0150] Part #1 was added to a 500-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, a nitrogen blanket, and a heating mantle with a thermometer connected through a temperature feedback control device. The reaction mixture was heated to 60oC, at 60oC, Part #2 was added into flask over 1 hours. Then the reaction mixture was heated to 75oC. The reaction mixture was maintained at 75oC until IR spectroscopy showed the absence of the characteristic NCO band (2269 cm-1) using the Thermo Scientific Nicolet iS5 FT-IR. The reaction product was poured out at 70°C.

[0151] The molecular weight of rheology modifier A was 3738 g / mol, as determined by Gel Permeation Chromatography using Waters 2695 separation module with a Waters 410 differential refractometer (RI detector), using polystyrene standards, tetrahydrofuran (THF) as the eluent at a flow rate of 1 ml min-1, and two PL Gel Mixed C columns for separation.

[0152] Rheology Modifier B Table 2: Formulation of Rheology Modifier B Component Grams (g) Wt. % Part 11Vestanat T mber 53880-05- 0.2Dibutyl tin dilaurate is commercially available from Evonik Industries.312-Hydroxy Stearic acid is commercially available from AZEVEDO INDUSTRY.

[0153]

[0154] Part #1 was added to a 500-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, a nitrogen blanket, and a heating mantle with a thermometer connected through a temperature feedback control device. The reaction mixture was heated to 90oC. At 90oC, Part #2 was added into flask over 1 hours. Then the reaction mixture was heated to 105oC. The reaction mixture was maintained at 105oC until IR spectroscopy showed the absence of the characteristic NCO band (2269 cm-1) using the Thermo Scientific Nicolet iS5 FT-IR. The reaction product was poured out at 100°C.

[0155] The molecular weight of rheology modifier B was 3975 g / mol, as determined by Gel Permeation Chromatography using Waters 2695 separation module with a Waters 410 differential refractometer (RI detector), using polystyrene standards, tetrahydrofuran (THF) as the eluent at a flow rate of 1 ml min-1, and two PL Gel Mixed C columns for separation.

[0156] Rheology Modifier CTable 3: Formulation of Rheology Modifier C Component Grams (g) Wt. % Part 11Vestanat T mber 53880-05- 0.2Dibutyl tin dilaurate is commercially available from Evonik Industries.312-Hydroxy Stearic acid is commercially available from AZEVEDO INDUSTRY.41,6-hexanediol is commercially available from BASF.5Butyl acetate solvent, CAS number 123-86-4

[0157]

[0158] Part #1 was added to a 2000-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, a nitrogen blanket, and a heating mantle with a thermometer connected through a temperature feedback control device. The reaction mixture was heated to 70oC. Once the solid material is completely dissolved, reaction mixture was cooled to 65oC. At 65oC, part #2 was added into flask over 1 hours. Then the reaction mixture was heated to 90oC. The reaction mixture was maintained at 90oC until the NCO Equivalent weight was stalled 2187. Part #3 was added into reaction mixture. Then the reaction mixture was heated to 105oC. The reaction mixture was maintained at 105oC until IR spectroscopy showed the absence of the characteristic NCO band (2269 cm-1) using the Thermo Scientific Nicolet iS5 FT-IR. Vacuum distillation was set up to remove the solvents and the resin was poured out from flask at 105oC.

[0159] As used herein, the “NCO equivalent weight” may be determined by titration of a sample using a Metrohm 808 or 888 Titrando, using a sample 1 g per 420 g / eq of predictedNCO equivalent weight and dissolving the sample in 30mL of a solution comprised of 20 mL of dibutylamine and 980 mL of n-methyl pyrrolidone, followed by titration with 0.2 N HCl solution in isopropanol titration agent.

[0160] The molecular weight of rheology modifier C was 27860 g / mol, as determined by Gel Permeation Chromatography using Waters 2695 separation module with a Waters 410 differential refractometer (RI detector), using polystyrene standards, tetrahydrofuran (THF) as the eluent at a flow rate of 1 ml min-1, and two PL Gel Mixed C columns for separation.

[0161] Rheology Modifier D Table 4: Formulation of Rheology Modifier D Ingredients Parts by weight Wt. % Part 11DESMOD .2Dibutyl tinaura e s commerc a y ava a e rom von n us r es.312-Hydroxy Stearic acid is commercially available from AZEVEDO INDUSTRY.4Butyl acetate, CAS number 123-86-4

[0162]

[0163] Part #1 was added to a 1000-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, a nitrogen blanket, and a heating mantle with a thermometer connected through a temperature feedback control device. The reaction mixture was heated to 70oC, At 70oC, Part #2 was added into flask over 1 hours. Then the reaction mixture was heated to 75oC. The reaction mixture was maintained at 75oC until IR spectroscopy showed the absence of the characteristic NCO band (2269 cm-1) using the Thermo Scientific Nicolet iS5 FT-IR. Vacuum distillation was set up to remove the solvents and the resin was poured out from flask at 105oC.

[0164] The molecular weight of rheology modifier D was 38410 g / mol, as determined by Gel Permeation Chromatography using Waters 2695 separation module with a Waters 410 differential refractometer (RI detector), using polystyrene standards, tetrahydrofuran (THF) as the eluent at a flow rate of 1 ml min-1, and two PL Gel Mixed C columns for separation.

[0165] Rheology Modifier E Table 5: Formulation of Rheology Modifier E Ingredients Parts by weight Wt. % Part 1112-Hydrox Y.2E-Caprolacone s commerc a y ava a e rom .3Stannous octoate is commercially available from TIB CHEMICALS.4Dibutyl tin dilaurate is commercially available from Evonik Industries.5DESMODUR N3790 is a HDI trimer and commercially available from Covestro.

[0166]

[0167] Part #1 was added to a 500-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, a nitrogen blanket, and a heating mantle with a thermometer connected through a temperature feedback control device. The reaction mixture was heated to 130oC, Reaction mixture was maintained at reflux until IR spectroscopy showed the absence of the characteristic E-caprolactone bands ( 850 and 860 cm-1) using the Thermo Scientific Nicolet iS5 FT-IRoC. The reaction mixture was cooled to 75oC. At 75oC, Part #2 was added into flask and followed by Part #3 over 1 hours. Then the reaction mixture was heated to 75oC . The reaction mixture was maintained at 75oC until IR spectroscopy showed the absence of the characteristic NCO band (2269 cm-1) using the ThermoScientific Nicolet iS5 FT-IR. Vacuum distillation was set up to remove the solvents and the resin was poured out from flask at 105oC.

[0168] The molecular weight of rheology modifier E was 55537 g / mol, as determined by Gel Permeation Chromatography using Waters 2695 separation module with a Waters 410 differential refractometer (RI detector), using polystyrene standards, tetrahydrofuran (THF) as the eluent at a flow rate of 1 ml min-1, and two PL Gel Mixed C columns for separation.

[0169] Rheology Modifier F Table 6: Formulation of Rheology Modifier F Ingredients Parts by weight Wt. % Part 11DESMOD o.2Dibutyl tin3Isostearyl alcohol is commercially available from Ambeed.

[0170]

[0171] Part #1 was added to a 1000-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, a nitrogen blanket, and a heating mantle with a thermometer connected through a temperature feedback control device. The reaction mixture was heated to 70oC, At 70oC, Part #2 was added into flask over 1 hours. Then the reaction mixture was heated to 75oC. The reaction mixture was maintained at 75oC until IR spectroscopy showed the absence of the characteristic NCO band (2269 cm-1) using the Thermo Scientific Nicolet iS5 FT-IR. Vacuum distillation was set up to remove the solvents and the resin was poured out from flask at 105oC.

[0172] The molecular weight of rheology modifier F was 4099 g / mol, as determined by Gel Permeation Chromatography using Waters 2695 separation module with a Waters 410 differential refractometer (RI detector), using polystyrene standards, tetrahydrofuran (THF) as the eluent at a flow rate of 1 ml min-1, and two PL Gel Mixed C columns for separation.EXAMPLE 2: COATING COMPOSITIONS 1-24 AND COMPARATIVE 1-15 COATING COMPOSITION FORMULATIONS

[0173] Coating compositions 1-24 and comparative (comp.) coating compositions 1-15 were formulated according to Tables 7A-7G. The exemplary (ex.) wt. % and a range of potential wt. %s are presented in the tables below, based on the total weight of the coating composition.

[0174] All coating compositions were extruded at 80oC with a targeted torque of 50. After extrusion, the coating compositions were ground to an average particle size of 30 µm and passed through a 170 mesh sieve. Tables 7A: Formulations of Coating Compositions 1-3 and Comp. Coating Compositions 1- 3 (wt. %) Comp.1 Comp.2 Comp.3 Ex.1 Ex.2 Ex.3 C ge %) t P 83 R E t C 2 F L .5 R 25- C B PComp.1 Comp.2 Comp.3 Ex.1 Ex.2 Ex.3 Component Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range %) B S 0 F F - 1 2 34 Resiflow PL-200 manufactured by Estron Chemicals, 65-70% proprietary material in 30-35% CAS Number 112926-00-8 5 Printex G manufactured by Orion Engineered Carbons, CAS Number: 1333-86-4 6 VBF Micro 1 manufactured by Kish Company. CAS Number:7727-43-7 7 Aeroxide Alu C, manufactured by Evonik , CAS number 1344-28-1 Tables 7B: Formulations of Coating Compositions 4-9 (wt. %) Ex.4 Ex.5 Ex.6 Ex.7 Ex.8 Ex.9 ange wt%) t P 3-83 E t 4-7 2 -1 F L 1-1.5Ex.4 Ex.5 Ex.6 Ex.7 Ex.8 Ex.9 Component Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range wt%) .125- 0-2 P S -40 F F 0.1- .2 1 23 Benzion manufactured by Huangshan Linlu Coatings Materials, CAS number 119-53-9. 4 Resiflow PL-200 manufactured by Estron Chemicals, 65-70% proprietary material in 30-35% CAS Number 112926-00-8 5 Printex G manufactured by Orion Engineered Carbons, CAS Number: 1333-86-4 6 VBF Micro 1 manufactured by Kish Company. CAS Number:7727-43-7 7 Aeroxide Alu C, manufactured by Evonik , CAS number 1344-28-1 Tables 7C: Formulations of Coating Compositions 10-15 (wt. %) 5 ange wt%) t P 3-83 E t 4-7 2Ex.10 Ex.11 Ex.12 Ex.13 Ex.14 Ex.15 Component Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range wt%) -1 F L 1-1.5 .125- 0-2 P S -40 F F 0.1- .2 1 2 Triglycidyl isocyanurate (TGIC) manufactured by Huangshan Linlu Coatings Materials, CAS number 2451-62-9, 3 Benzion manufactured by Huangshan Linlu Coatings Materials, CAS number 119-53-9. 4 Resiflow PL-200 manufactured by Estron Chemicals, 65-70% proprietary material in 30-35% CAS Number 112926-00-8 5 Printex G manufactured by Orion Engineered Carbons, CAS Number: 1333-86-4 6 VBF Micro 1 manufactured by Kish Company. CAS Number:7727-43-7 7 Aeroxide Alu C, manufactured by Evonik , CAS number 1344-28-1 Tables 7D: Formulations of Comp. Coating Compositions 4-6 (wt. %)Comp.4 Comp.5 Comp.6 Component Range Range Ex. Range %) 3 5 -5 0.2 1 Rucote 92 Triglycidyl isocyanurate (TGIC) manufactured by Huangshan Linlu Coatings Materials, CAS number 2451-62-9, 3 Benzion manufactured by Huangshan Linlu Coatings Materials, CAS number 119-53-9. 4 Resiflow PL-200 manufactured by Estron Chemicals, 65-70% proprietary material in 30-35% CAS Number 112926-00-8 5 Printex G manufactured by Orion Engineered Carbons, CAS Number: 1333-86-4 6 VBF Micro 1 manufactured by Kish Company. CAS Number:7727-43-7 7 Aeroxide Alu C, manufactured by Evonik , CAS number 1344-28-1 Tables 7E: Formulations of Coating Compositions 16-18 and Comp. Coating Compositions 7-9 (wt. %)Comp.7 Comp.8 Comp.9 Ex.16 Ex.17 Ex.18 Component Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range Ex. Range wt%) E 9-87 2.5- .5 -1 F L 1-1.5 .125- P 0-2 F -35 F 0.1- .2 12 Dyhard 100S manufactured by Alzchem LLC, CAS number 461-58-5 3 Benzion manufactured by Huangshan Linlu Coatings Materials, CAS number 119-53-9. 4 Resiflow PL-200 manufactured by Estron Chemicals, 65-70% proprietary material in 30-35% CAS Number 112926-00-8 5 Printex G manufactured by Orion Engineered Carbons, CAS Number: 1333-86-4 6 VBF Micro 1 manufactured by Kish Company. CAS Number:7727-43-7 7 Aeroxide Alu C, manufactured by Evonik , CAS number 1344-28-1Tables 7F: Formulations of Coating Compositions 19-21 and Comp. Coating Compositions 10-12 (wt. %) Comp.10 Comp.11 Comp.12 Ex.19 Ex.20 Ex.21 Component Range wt%) t P 8-44 E 8-44 -1 F L 1-1.5 .125- P 0-2 S 0-40 F 0.1- .2 12 KD-242G manufactured by Kukdo Chemical Co, Ltd., CAS number 25036-25-3 3 Benzion manufactured by Huangshan Linlu Coatings Materials, CAS number 119-53-9. 4 Resiflow PL-200 manufactured by Estron Chemicals, 65-70% proprietary material in 30-35% CAS Number 112926-00-8 5 Printex G manufactured by Orion Engineered Carbons, CAS Number: 1333-86-4 6 VBF Micro 1 manufactured by Kish Company. CAS Number:7727-43-7 7 Aeroxide Alu C, manufactured by Evonik , CAS number 1344-28-1Tables 7G: Formulations of Coating Compositions 22-24 and Comp. Coating Compositions 13-15 (wt. %) Comp.13 Comp.14 Comp.15 Ex.22 Ex.23 Ex.24 Component Range wt%) E t 0-82 t .5- 1.5 -1 F L 1-1.5 .125- S F F 0.1- .2 12 Dodecanedioic Acid manufactured by Evonik Industries, CAS number 693-23-2 3 Benzion manufactured by Huangshan Linlu Coatings Materials, CAS number 119-53-9. 4 Resiflow PL-200 manufactured by Estron Chemicals, 65-70% proprietary material in 30-35% CAS Number 112926-00-8 5 VBF Micro 1 manufactured by Kish Company. CAS Number:7727-43-7 6 Aeroxide Alu C, manufactured by Evonik , CAS number 1344-28-1EXAMPLE 3: PERFORMANCE OF COATING COMPOSITIONS 1-24 AND COMPARATIVE COATING COMPOSITIONS 1-15

[0175] The physical properties of the coating compositions of the present disclosure and comparative coating compositions were tested at the curing temperature and time specified, as shown in Tables 8A-8G. All tests were performed according to the methods described above. Table 8A: Properties of Coating Compositions 1-3 and Comp. Coating Compositions 1-3 Measurement Comp. 1 Comp.2 Comp.3 Ex.1 Ex.2 Ex.3 Curing Temp [°C] / Time [min] 191 / 20 191 / 20 191 / 20 191 / 20 191 / 20 191 / 20 5 a 1 V 2 V correspond to surface too rough to gather measurement. 3 Values gathered using a TRICOR DOI / Haze Meter (Model 807A), an average of 3 measurements per panel. 4 Smoothness rating compared to ACT powder smoothness standards (Item No.22163), an average from 3 different reviewers. 5 Measurement gathered acording to ASTM D4217. 6 Measurement gathered acording to ASTM D4242. Table 8B: Properties of Coating Compositions 4-9 Measurement Ex.4 Ex.5 Ex.6 Ex.7 Ex.8 Ex.9 C [ [ [ S a P (1 Values gathered using a BYK TriGloss (Serial No.1103923), an average of 3 measurements per panel. 2 Values gathered using a BYK WaveScan (Model 4806), an average of 3 measurments per panel. NA values correspond to surface too rough to gather measurement. 3 Values gathered using a TRICOR DOI / Haze Meter (Model 807A), an average of 3 measurements per panel. 4 Smoothness rating compared to ACT powder smoothness standards (Item No.22163), an average from 3 different reviewers. 5 Measurement gathered acording to ASTM D4217. 6 Measurement gathered acording to ASTM D4242. Table 8C: Properties of Coating Compositions 10-15 Measurement Ex.10 Ex.11 Ex.12 Ex.13 Ex.14 Ex.15 Curing Temp [°C] / Time 191 / 20 191 / 20 191 / 20 191 / 20 191 / 20 191 / 20 [ [ S a P ( 1 2correspond to surface too rough to gather measurement. 3 Values gathered using a TRICOR DOI / Haze Meter (Model 807A), an average of 3 measurements per panel. 4 Smoothness rating compared to ACT powder smoothness standards (Item No.22163), an average from 3 different reviewers. 5 Measurement gathered acording to ASTM D4217. 6 Measurement gathered acording to ASTM D4242. Table 8D: Properties of Comp. Coating Compositions 4-6 Measurement Comp.4 Comp. 5 Comp. 6Measurement Comp.4 Comp. 5 Comp. 6 Plate Flow 119 69 48 (mm) at Cure T61 Values gathered usin ents per panel. 2 Values gathered usin er panel. NA values correspond to surface t 3 Values gathered usinasurements per panel. 4 Smoothness rating compared to ACT powder smoothness standards (Item No.22163), an average from 3 different reviewers. 5 Measurement gathered acording to ASTM D4217. 6 Measurement gathered acording to ASTM D4242. Table 8E: Properties of Coating Compositions 16-18. Coating Compositions 7-9 Measurement Comp.7 Comp. 8 Comp. 9 Ex.16 Ex.17 Ex.18 Curing Temp [° 0 [ [ S a P ( 1 2, . correspond to surface too rough to gather measurement. 3 Values gathered using a TRICOR DOI / Haze Meter (Model 807A), an average of 3 measurements per panel. 4 Smoothness rating compared to ACT powder smoothness standards (Item No.22163), an average from 3 different reviewers. 5 Measurement gathered acording to ASTM D4217. 6 Measurement gathered acording to ASTM D4242. Table 8F: Properties of Coating Compositions 19-21. Coating Compositions 10-12 M r m nt C m 10 C m 11 C m 12 Ex 19 Ex 20 Ex 21 [ [ [Measurement Comp.10 Comp. 11 Comp. 12 Ex.19 Ex.20 Ex.21 DOI366 33 83 28 Smoothness 7 8 3 9 8 2 R4a P ( 1 2 co 3 Vaues ga ere us ng a CO O / aze eer ( o e 80 ), an average o 3 measuremen s per pane. 4 Smoothness rating compared to ACT powder smoothness standards (Item No.22163), an average from 3 different reviewers. 5 Measurement gathered according to ASTM D4217. 6 Measurement gathered according to ASTM D4242. Table 8G: Properties of Coating Compositions 22-24. Coating Compositions 13-15 Measurement Comp.13 Comp. 14 Comp. 15 Ex.22 Ex.23 Ex.24 Curing Temp [ [ [ S a P ( 12 Values gathered using a BYK WaveScan (Model 4806), an average of 3 measurments per panel. NA values correspond to surface too rough to gather measurement. 3 Values gathered using a TRICOR DOI / Haze Meter (Model 807A), an average of 3 measurements per panel. 4 Smoothness rating compared to ACT powder smoothness standards (Item No.22163), an average from 3 different reviewers. 5 Measurement gathered according to ASTM D4217. 6 Measurement gathered according to ASTM D4242.

[0176] Coating composition examples 1-15 demonstrate the ability for the acid- functional urethane rheology modifier to decrease the Plate Flow from a comparative system (Comp.1-3) while maintaining a smooth appearance (PCI smoothness rating greater than 6).Comp. examples 4-6 contain rheology modifier F which does not contain a linear aliphatic segment (12-hydroxy stearic acid), and the Plate Flow is not decreased from the initial comparative systems (Comp.1-3). Furthermore these rheology modifier work across different resin systems including epoxy resin (Ex.16-18), epoxy-polyester hybrids (Ex.19-21), and acrylic (Ex.22-24)”

[0177] Wherein particular examples of this disclosure have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from the disclosure as defined in the appended claims. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims. ASPECTS

[0178] Aspect 1 is a coating composition, comprising: a binder resin; a crosslinker; one or more fillers; and an acid functional urethane rheology modifier.

[0179] Aspect 2 is the coating composition of Aspect 1, wherein the rheology modifier is the reaction product of a hydroxy functional acid and a polyisocyanate.

[0180] Aspect 3 is the coating composition of Aspect 2, wherein the hydroxy functional acid is 12-hydroxy stearic acid.

[0181] Aspect 4 is the coating composition of any one of the proceeding Aspects, wherein the binder resin is at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin.

[0182] Aspect 5 is the coating composition of any one of the proceeding Aspects, wherein the coating composition comprises: 50 wt. % to 90 wt. % of the binder resin; 1 wt. % to 8 wt. % of the crosslinker; 0.5 wt. % to 5.0 wt. % rheology modifier; and 10 wt. % to 30 wt. % of the one or more fillers, based on the total weight of the coating composition.

[0183] Aspect 6 is the coating composition of any one of the proceeding Aspects, wherein the filler comprises one of, or a combination of an inorganic filler, an organic filler, a pigment, a colorant, and an additive.

[0184] Aspect 7 is the coating composition of any one of the proceeding Aspects, wherein the filler comprises an additive, the additive comprising at least one of a degassing agent, a flow agent, a catalyst, an adhesion promotor, or a mixture thereof.

[0185] Aspect 8 is the coating composition of any one of the proceeding Aspects, wherein the filler comprises one of, or combination of, carbon black, barium sulfate, and / or aluminum oxide.

[0186] Aspect 9 is the coating composition of any one of the proceeding Aspects, wherein the crosslinker comprises at least one of an acid-reactive curative; epoxy reactive curative; hydroxyl reactive curative; hydroxylalkylurea (HAU); and a blocked isocyanate.

[0187] Aspect 10 is the coating composition of any one of the proceeding Aspects, wherein the crosslinker is at least one of a triglycidyl isocyanurate and a hydroxyalkylamid.

[0188] Aspect 11 is the coating composition of any one of the proceeding Aspects, wherein the polyester resin is an acid functional polyester resin.

[0189] Aspect 12 is a coating composition, comprising: a binder resin comprising at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin; and an acid functional urethane rheology modifier formed from the reaction of a hydroxy functional acid and a polyisocyanate.

[0190] Aspect 13 is the coating composition of Aspect 12, wherein the hydroxy functional acid is 12-hydroxy stearic acid.

[0191] Aspect 14 is the coating composition of Aspect 12 or Aspect 13, further comprising a filler.

[0192] Aspect 15 is the coating composition of Aspect 14, wherein the filler comprises one of, or a combination of an inorganic filler, an organic filler, a pigment, a colorant, and an additive.

[0193] Aspect 16 is the coating composition of Aspect 15, wherein the filler comprises an additive, the additive comprising at least one of a degassing agent, a flow agent, a catalyst, an adhesion promotor, or a mixture thereof.

[0194] Aspect 17 is the coating composition of any one of Aspects 12-16, wherein coating composition comprises a particle size of at least 25 µm, as measured by ASTM D5861 (2017).

[0195] Aspect 18 is the coating composition of any one of Aspects 12-17, wherein the cured coating composition comprises a PCI value of greater than 7, as measured by ASTM D3451, section 32.8.2 (2017).

[0196] Aspect 19 is the coating composition of any one of Aspects 12-18, wherein the cured coating composition comprises a gloss of 80-85 at 20oand 90-95 at 60o, as measured using a glossmeter ASTM D523 (2018).

[0197] Aspect 20 is the coating composition of any one of Aspects 12-19, wherein the cured coating composition comprises a film thickness from 1 to 6 mils, as measured by ASTM D1005 (2020).

[0198] Aspect 21 is the coating composition of any one of Aspects 12-20, wherein the cured coating composition coated on a substrate surface comprises a percent edge corrosion of 0 to 20 %.

[0199] Aspect 22 is the coating composition of any one of Aspects 12-21, wherein the cured coating composition comprises a distinctiveness of image (DOI) of 40-65, as measured using a DOI / Haze meter.

[0200] Aspect 23 is a method of coating an article comprising: mixing a binder resin, an acid functional urethane rheology modifier, and a filler to form a coating composition; wherein the binder resin comprises at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin; wherein the filler comprises at least one of a pigment, a colorant, and an additive; and wherein the coating composition has a plate flow less than 50 mm at 191oC, as determined by ASTM D4242 (2017); and applying the coating composition onto a surface of the article, wherein the cured coating composition comprises a PCI value of greater than 7, as measured by ASTM D3451, section 32.8.2 (2017).

[0201] Aspect 24 is the method of Aspect 23, wherein the coating composition is applied in an electrostatic spray application process.

[0202] Aspect 25 is the method of Aspect 23, wherein the coating composition is applied in a fluidized bed immersion process.

[0203] Aspect 26 is the method of Aspect 23, wherein the coating composition is applied in a thermal spray application process.

[0204] Aspect 27 is the method of Aspect 26, further comprising heating the coating composition to a temperature of 150-250oC for 10-180 minutes.

[0205] Aspect 28 is the method of any one of Aspects 23-27, wherein the coating composition comprises the coating composition of any one of Aspects 1-20.

Claims

CLAIMS What is claimed is:

1. A coating composition, comprising: a binder resin; a crosslinker; one or more fillers; and an acid functional urethane rheology modifier.

2. The coating composition of claim 1, wherein the rheology modifier is the reaction product of a hydroxy functional acid and a polyisocyanate; wherein the hydroxy functional acid is 12-hydroxy stearic acid.

3. The coating composition of any one of the proceeding claims, wherein the binder resin is at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin.

4. The coating composition of any one of the preceding claims, wherein the coating composition comprises: 50 wt. % to 90 wt. % of the binder resin; 1 wt. % to 8 wt. % of the crosslinker; 0.5 wt. % to 5.0 wt. % rheology modifier; and 10 wt. % to 30 wt. % of the one or more fillers, based on the total weight of the coating composition.

5. The coating composition of any one of the preceding claims, wherein the filler comprises one of, or a combination of an inorganic filler, an organic filler, a pigment, a colorant, and an additive.

6. The coating composition of claim 6, wherein the filler comprises an additive, the additive comprising at least one of a degassing agent, a flow agent, a catalyst, an adhesion promotor, carbon black, barium sulfate, aluminum oxide, or a mixture thereof.

7. The coating composition of any one of the preceding claims, wherein the crosslinker comprises at least one of an acid-reactive curative; epoxy reactive curative; hydroxyl reactive curative; hydroxylalkylurea (HAU); and a blocked isocyanate.

8. The coating composition of any one of the preceding claims, wherein the crosslinker is at least one of a triglycidyl isocyanurate and a hydroxyalkylamid.

9. The coating composition of any one of the preceding claims, wherein the polyester resin is an acid functional polyester resin.

10. A coating composition, comprising: a binder resin comprising at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin; and an acid functional urethane rheology modifier formed from the reaction of a hydroxy functional acid and a polyisocyanate.

11. The coating composition of claim 10, wherein the hydroxy functional acid is 12-hydroxy stearic acid.

12. The coating composition of either claim 10 or claim 11, further comprising a filler; wherein the filler comprises one of, or a combination of an inorganic filler, an organic filler, a pigment, a colorant, and an additive.

13. The coating composition of claim 12, wherein the filler comprises an additive, the additive comprising at least one of a degassing agent, a flow agent, a catalyst, an adhesion promotor, or a mixture thereof.

14. The coating composition of any one of claims 10-13, wherein coating composition comprises at least one of:a particle size of at least 25 µm, as measured by ASTM D5861 (2017); and a PCI value of greater than 7, as measured by ASTM D3451, section 32.8.2 (2017).

15. The coating composition of any one of claims 10-14, wherein the cured coating composition comprises at least one of: a gloss of 80-85 at 20oand 90-95 at 60o, as measured using a glossmeter ASTM D523 (2018); a film thickness from 1 to 6 mils, as measured by ASTM D1005 (2020); and wherein the cured coating composition comprises a distinctiveness of image (DOI) of 40- 65, as measured using a DOI / Haze meter.

16. The coating composition of any one of claims 10-15, wherein the cured coating composition coated on a substrate surface comprises a percent edge corrosion of 0 to 20 %.

17. A method of coating an article comprising: mixing a binder resin, an acid functional urethane rheology modifier, and a filler to form a coating composition; wherein the binder resin comprises at least one of a polyester resin, an epoxy resin, an acrylic resin, and a polyester epoxy hybrid resin; wherein the filler comprises at least one of a pigment, a colorant, and an additive; and wherein the coating composition has a plate flow less than 50 mm at 191oC, as determined by ASTM D4242 (2017); and applying the coating composition onto a surface of the article, wherein the cured coating composition comprises a PCI value of greater than 7, as measured by ASTM D3451, section 32.8.2 (2017). .

18. The method of claim 17, wherein the coating composition is applied in an electrostatic spray application process.

19. The method of claim 17, wherein the coating composition is applied in a fluidized bed immersion process.

20. The method of claim 17, wherein the coating composition is applied in a thermal spray application process and then heated to a temperature of 150-250oC for 10-180 minutes.

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