Two-component durable, impact-resistant coating against hostile media

Abstract

A two-part coating comprising a part A including an epoxy resin composition comprising a phenoxy resin, and a part B including at least one room temperature curative composition, wherein the part A includes an amine terminated elastomer modified epoxy and / or thiol terminated elastomer modified epoxy and / or the Part B includes an amine terminated elastomer and / or thiol terminated elastomer.

Description

Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOTWO-COMPONENT DURABLE, IMPACT-RESISTANT COATING AGAINST HOSTILE MEDIACLAIM OF PRIORITY

[0001] This application claims the benefit of the filing date of United States Provisional Application Serial No.63 / 700,791, filed on September 30, 2024. The contents of that application are hereby incorporated by reference herein in their entirety and for all purposes.FIELD OF INVENTION

[0002] The present teachings relate generally to two-component coating formulations that cure at room temperature. The coatings provide improved protection of metals against a variety of hostile media.BACKGROUND

[0003] Anti-corrosive coatings have been widely used in different industries including aerospace, automotive, submarine construction, marine or yacht, chemical containment, battery electrode protection, and other related industries.

[0004] Over the years, chromates have been widely used as anti-corrosive coatings due to their outstanding performance in corrosion protection. However, the toxicity and carcinogenicity of chromates has become a tremendous problem for acceptance in certain regions and has led these coatings to be heavily regulated, especially in Europe. As such, alternative corrosion inhibitors have been extensively investigated for anti-corrosive coating applications. For example, zirconium- and titanium-based conversion coatings have been commercialized and implemented in automotive industry. Cerium-based conversion coatings have been found to be effective at improving corrosion resistance of aluminum alloys.

[0005] Additionally, organic coatings including polychloroprene and chlorosulfonated polyethylene-based coatings have also demonstrated high chemical resistance. Their wide range of application is hindered due to the need of solvents and the consequent environmental concerns to prepare a liquid formulation. Other organic coatings including acrylic, silane-based so-gel, nitrocellulose, hydroxyl terminated polyether have also been investigated for anti-corrosive applications. However, none of these coatings provide sufficient chemical resistance.1Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WO

[0006] The present teachings, therefore, seek to provide solvent-free and chromate-free room temperature cured epoxy coatings as protective layers against a wide spectrum of common media including harsh corrosive media (e.g., highly concentrated sodium hydroxide).SUMMARY OF INVENTION

[0007] The teachings herein are directed to a two-part coating comprising a part A including an epoxy resin composition comprising a phenoxy resin, a part B including at least one room temperature curative composition, wherein the part A includes an amine terminated elastomer modified epoxy and / or thiol terminated elastomer modified epoxy and / or the Part B includes an amine terminated elastomer and / or thiol terminated elastomer.

[0008] The part A may include a silane-modified epoxy resin in the range of about 0.5% to about 70% by weight of the part A.

[0009] The phenoxy resin may be present in an amount of from 0.5% to 20% by weight of the part A.

[0010] The part A may include an elastomer / epoxy adduct in the range of from 1% to 60% by weight of the part A.

[0011] The part B may include at least one multifunctional room temperature curative in the range of 0.5% to 97% by weight of the part B.

[0012] The part B may comprise an amine or thiol-terminated elastomer in the range of about 2% to 40% by weight of the part B.

[0013] The part B may comprise a difunctional chain extender in the range of about 0.5% to about 30% by weight of the part B.

[0014] The two-part coating may include an epoxy / diacid adduct present in an amount of from about 0.2% to about 25% by weight, or even from about 6% to about 10% by weight of the part A.

[0015] The two-part coating may include a polymeric particle present in an amount of at least about 3% but less than about 60% by weight, or even at least about 10% but less than about 32% by weight of the part A.

[0016] The two-part coating may comprise a flexibilizer in the range of about 2% to about 50% by weight of the part A and / or the part B.2Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WO

[0017] The room temperature curative composition may be selected from the group consisting of an amine, an amine derivative, a polyamide, a mercaptan, a mercaptan derivative or any combination thereof.

[0018] The elastomer in the epoxy / elastomer adduct may be selected from the group consisting of amine-terminated butadiene-acrylonitrile (ATBN), carboxyl-terminated butadiene-acrylonitrile (CTBN), epoxy-terminated butadiene-acrylonitrile (ETBN), di or multi-mercaptan, polysulfide, or combinations thereof.

[0019] The two-part coating may include a difunctional chain extender selected from selected from 1-naphthylamine, 2-naphthylamine, ethanolamine, phenethylamine, oleylamine, dimercaptans (e.g., 2,2′-(ethylenedioxy)diethanethiol and 1,2-ethanedithiol), or any combination thereof.

[0020] The two-part coating may include an epoxy / diacid adduct wherein the diacid component is selected from a C18 diacid, a C36 diacid, or any combination thereof.

[0021] The two-part coating may comprise a flexibilizer wherein the flexibilizer is a stand-alone component or is adducted with epoxy and is selected from, phenol terminated urethane, Epoxonic 328 or any combination thereof.

[0022] The polymeric particle may include core modifiers of polybutadiene, styrene-butadiene rubber, or a combination thereof.

[0023] The polymeric particle may include core / shell rubber particles averaging about 100-200 nm in size.

[0024] The polymeric particle may be substantially free of agglomerated particles.

[0025] The two-part coating may include one or more fillers or fibers.

[0026] The one or more fillers or fibers may be selected from the group consisting of silica, diatomaceous earth, glass, clay, glass beads or bubbles, glass, carbon or ceramic fibers, nylon, aramid or polyamide fibers, pyrophyllite, sauconite, saponite, nontronite, wollastonite, and montmorillonite and combinations thereof.

[0027] The two-part coating may include a silica and / or calcium-based filler.

[0028] The silica-based filler may be fumed silica.

[0029] The teachings herein are further directed to a two-part coating comprising a part A including an epoxy resin composition comprising phenoxy resin, a Part B including a curative3Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOcomposition adapted to cure the two-part coating at room temperature, wherein the part A includes an amine terminated elastomer modified epoxy and a thiol terminated elastomer modified epoxy.

[0030] The part A may include a silane-modified epoxy resin in the range of about 0.5% to about 70% by weight of the part A.

[0031] The ratio of part A to part B may be about 2:1. The ratio of part A to part B may be about 1:1.

[0032] Part A may include a polysulfide adduct and a silane-modified epoxy.

[0033] Part A includes a liquid elastomer adduct and the phenoxy resin and the thiol terminated elastomer modified epoxy are present in a ratio of from about 2:1 to about 1:2.

[0034] The teachings herein are also directed to a two-part coating comprising a part A including an epoxy resin composition comprising phenoxy resin, a part B including at a curative composition adapted to cure the two-part coating at room temperature, wherein the part B includes an amine terminated elastomer and a thiol terminated elastomer. The part A includes a silane-modified epoxy resin in the range of about 0.5% to about 70% by weight of the part A.

[0035] The two-part coating may be substantially free of any component requiring heat for curing.BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Fig1A is a graphic depiction of an aluminum plate having a protective layer applied on top and side surfaces.

[0037] Fig1B is a graphic depiction of an aluminum plate having a uniform or controlled erosion.

[0038] Fig1C is a graphic depiction of an aluminum plate having an undesirable undercutting erosion.

[0039] Fig2A is an image of Sample 1 after exposure to 6N NaOH for 24 hours.

[0040] Fig2B is an image of Sample 1 after exposure to 6N NaOH for 24 hours.

[0041] Fig2C is an image of Sample 2 after exposure to 6N NaOH for 24 hours.

[0042] Fig2D is an image of Sample 3 after exposure to 6N NaOH for 24 hours.

[0043] Fig2E is an image of Sample 4 after exposure to 6N NaOH for 24 hours.

[0044] Fig2F is an image of Sample 5 after exposure to 6N NaOH for 24 hours.

[0045] Fig2G is an image of Sample 6 after exposure to 6N NaOH for 24 hours.

[0046] Fig2H is an image of Sample 7 after exposure to 6N NaOH for 24 hours.

[0047] Fig 3A is an image of Sample 8 after exposure for 7 days to 2.5% ammonia.4Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WO

[0048] Fig 3B is an image of Sample 8 after exposure for 7 days to Manure.

[0049] Fig 3C is an image of Sample 8 after exposure for 7 days to Xylene.

[0050] Fig 3D is an image of Sample 8 after exposure for 7 days to 5% sodium hydroxide.

[0051] Fig 4A is an image of Sample 9 after exposure for 7 days to 2.5% ammonia.

[0052] Fig 4B is an image of Sample 9 after exposure for 7 days to Manure.

[0053] Fig 4C is an image of Sample 9 after exposure for 7 days to Xylene.

[0054] Fig 4D is an image of Sample 9 after exposure for 7 days to 5% sodium hydroxide.DETAILED DESCRIPTION

[0055] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the present teachings, its principles, and its practical application. The specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the present teachings. The scope of the present teachings should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description. Percentages herein refer to weight percent, unless otherwise indicated.

[0056] The material of the present teachings may be applied to various articles of manufacture for adding corrosion resistance to portions or members of the articles. Examples of such articles of manufacture include, without limitation, aerospace, automotive, submarine construction, boating, household or industrial appliances, furniture, storage containers, buildings, batteries, generators, or the like

[0057] The present teachings are directed to combining low shrinkage upon curing, chemical resistance, and adhesion improvement to prepare room temperature cure coatings against a wide range of hostile media.

[0058] The part B comprises at least the curative composition. The part B may comprise at least one or more polyamine curatives, one or more polyamide curatives, or a combination thereof. Non-limiting examples of each include Ancamine® and Ancamide® available from Evonik Industries). Certain polyamide curatives (e.g., Ancamide 2767) may improve corrosion resistance and solvent5Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOresistance. The curative composition may be included in an amount of up to about 96% by weight of the part B. It may be approximately at least about 30% by weight, more typically at least about 40% by weight, more typically at least about 50% by weight of the part B. It may be approximately about 60% or more by weight, more typically about 75% or more by weight, more typically about 80% or more by weight, and even more typically 95% or more by weight of the part B.

[0059] The part A comprises at least an epoxy resin composition. The epoxy resin composition may include one or more high molecular weight polymers such as phenoxy resin to increase the chemical resistant nature of the coating. High molecular weight polymers may also reduce crosslinking density of the coating, subsequently leading to less severe shrinkage. Phenoxy resins are high molecular weight thermoplastic condensation products of bisphenol-A and epichloro-hydrin and their derivatives. The phenoxy resins that may be employed may be of the basic formula:w, . resins may also be used. Examples of phenoxy resins that may be used are products marketed by Gabriel Performance Products. Examples of suitable materials are the PKHB, PKHC, PKHH, PKHJ, PKHP pellets and powder. Alternatively, phenoxy / polyester hybrids and epoxy / phenoxy hybrids may be used. In order to enhance the compounding of the coating, it is preferred that the phenoxy resin be supplied into the mixed composition as a solution. While any solvent may be used to decrease incorporation temperature during mixing, it is particularly preferred to use a low molecular weight epoxy resin as the solvent as this can be a reactive constituent in the coating and improve mechanical properties upon activation.

[0060] One or more phase separating elastomers may be included in either the side A, or side B, or both, depending on the mutual chemical stability of the ingredients. These materials impart flexibility and improve durability through the service life of epoxy coatings. These high-molecular weight adducts also enable reduced shrinkage upon curing.

[0061] The side B may comprise a phase separating amine-terminated elastomer. Non-limiting examples of amine-terminated elastomers include amine-terminated liquid rubber (ATBN), an6Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOexample of which is sold under the tradename Hypro 1300X16 ATBN available from Huntsman Advanced Materials. The amine-terminated elastomer may be present in an amount that is less than 60%, more typically less than 45% and even possibly less than 40% by weight of the side B, but more than 2%, more than 5%, or more than 15% by weight of the side B, although higher and lower values may also be possible.

[0062] The A side may also include one or more phase separating elastomers formed as an adduct with epoxy. Examples of preferred adducts or preferred components for producing the adduct include carboxyl terminated butadiene acrylonitrile (CTBN) based materials and / or epoxy terminated butadiene acrylonitrile (ETBN) based materials. One example is Hypro™ 1300X13NA (CTBN), commercially available from Huntsman Advanced Materials, which can be adducted with the diglycidyl ether of bisphenol-F or diglycidyl ether of bisphenol-A. Yet another example of a preferred epoxy / elastomer adduct is Hypro™ 1300X63 (ETBN (glycidyl-ester of butadiene and butadiene-acrylonitrile)).

[0063] Another example of elastomers that may be included in the side A or side B, include thiol-terminated elastomers. One such example is a chemical resistant polysulfide such as Thiokol™ and Thioplast® or their adduct with epoxy resins. Other thiol-containing suitable components include di- or multi-mercaptans which may include DMDO (2,2′-(Ethylenedioxy)diethanethiol) from Arkema Innovative Chemistry, and Thiocure GDMP ((Ethylene glycol bis(3-mercaptopropionate)) from Bruno Bock, the Capcure® and Gabepro® products from Huntsman Advanced Materials and Thiocure® products from Bruno Bock. Similar to the phase separating elastomers, these thiol-containing materials (e.g., elastomers) and their adducts can be included in curative side A or side B depending on the mutual chemical stability of the ingredients.

[0064] The aforementioned elastomers, elastomer adducts, and other thiol containing materials may be included in an amount of up to about 75% by weight of the side A (but less than 90%, less than 75%, or even less than 50% by weight of the side A). The elastomers and / or elastomer adducts may be approximately at least about 5% by weight, more typically at least about 20% by weight, more typically at least about 40% by weight of the side A or side B. The elastomers and / or elastomer adducts may be approximately about 75% or less by weight, more typically about 70% or less by weight, more typically about 65% or less by weight, and even more typically 60% or less by weight of the side A or side B. The elastomers and / or elastomer adducts may be a combination of two or more particular adducts. The elastomers and / or elastomer adducts may be7Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOsolid adducts, liquid adducts, semisolids at a temperature of 23 ºC, or may also be some combination thereof.

[0065] Another way to introduce reduced shrinkage is the use of one or more chain extenders, a small molecule with two functional groups (e.g., reactive hydrogen) that reacts with epoxy resin to extend the linear chain length of the epoxy resin molecule to produce a high-molecular weight polymer in-situ upon curing. In contrast to a multifunctional curative, chain extenders promote more of a plastic nature and can reduce the crosslinking density, decreasing shrinkage upon cure.

[0066] In the present teachings, relatively small amounts of chain extender may be used. Examples of chain extenders include mono-primary amines, di-secondary amines, and di-mercaptans. As one non-limiting example, mono-primary amines may include 1-naphthylamine, 2-naphthylamine, ethanolamine, phenethylamine, oleylamine, or a combination thereof. Examples of suitable di-mercaptans include DMDO (2,2′-(Ethylenedioxy)diethanethiol) from Arkema Innovative Chemistry, and Thiocure GDMP (Ethylene glycol bis(3-mercaptopropionate)) from Bruno Bock. The one or more chain extenders may be included in an amount of up to about 10% by weight of the part B. The one or more chain extenders may be approximately at least about 0.2% by weight, more typically at least about 1% by weight, more typically at least about 2% by weight of the part B. The one or more chain extenders may be approximately about 30% or less by weight, more typically about 10% or less by weight, more typically about 7% or less by weight, and even more typically 5% or less by weight of the part B.

[0067] The part A described herein may include one or more epoxy resins. The one or more epoxy resins may be added to increase the adhesion, optimize the rheological behavior, and provide strength to the material. Preferred epoxy resins may include modified epoxy resins. The one or more epoxy resins may be silane modified epoxy resins or silane-free epoxy resins. For example, a silane modified epoxy resin may aid in allowing the material to adhere to nonferrous metal, such as to aluminum. The silane modified epoxy resin may be a reaction product between of at least one epoxy resin and a silane compound. An example of a suitable silane-modified epoxy resin is Epokukdo KSR-177 (di-functional silane-modified epoxy resin) available from Kukdo Chemical. One exemplary epoxy resin may be a phenolic resin, which may be a novolac type or other type resin. One example of a suitable epoxy resins is Epotec® YDF 172LV (diglycidyl ether of bisphenol F (DGEBF)), available from Aditya Birla. Moreover, various mixtures of several different epoxy resins may be employed as well. The one or more epoxy resins may also or in the8Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOalternative be present in other formulation constituents such as the elastomer adducts addressed herein. The concentrations and type of epoxy resins present in the formulation components vary by manufacturer and the particular grade. The one or more epoxy resins may be present in the formulation components as adducts, unreacted epoxy, or a combination thereof.

[0068] The part A and the part B may include one or more fillers. The term fillers should be construes broadly and can be organic or non-organic additives which differ from the polymeric matrix to improve coating properties, change thixotropic properties, improve moisture resistance, reduce cost, or some combination thereof. These fillers include but are not limited to silicates (such as those sold under the trade names of Garamite® and Satintone®), clays, mica, talc, wollastonite (under the trade names of Nyglos®, Vansil® and Wollastocoat®), calcium carbonate, calcium oxide, calcium sulfate, fumed silica (under trade names of Aerosil® and Cab-o-sil®), hollow glass and polymer spheres, carbon black, and graphite. Other additives, agents, or performance modifiers may also be included in the A side and / or B side as desired, including but not limited to a UV resistant agent, a flame retardant, a heat stabilizer, a colorant, a processing aid, a lubricant or the like.

[0069] One or more flexibilizers may be included in the side A or side B, depending on the chemical stability of the one or more flexibilizers. The use of the term flexibilizer can relate to a single flexibilizer or a combination of multiple different flexibilizers. Although other flexibilizers may be employed, preferred flexibilizers include polymers that are epoxy modified or urethane-modified prepolymers, particularly those that are phenol capped, or any combination thereof. It is believed that when a polyurethane flexibilizer is included, the material may exhibit enhanced flexibility, and substantially maintain impact strength (e.g., impact resistance) at low temperatures, while minimizing the reduction of glass transition temperature (Tg) (e.g., as compared to other flexibilizers). Examples of a preferred flexibilizers may be a phenol-terminated urethane based flexibilizer, Rez-Cure® EP 1820 (available from Innovative Resin Systems). Typically, the flexibilizer is less than 50%, more typically less than 35% and even possibly less than 20% by weight of the side A and / or side B, although higher and lower values may also be possible unless otherwise stated.

[0070] The side A may include an epoxy / diacid adduct. The use of the term diacid can relate to any polyfunctional molecule having two carboxylic acid moieties. Some diacid compounds are introduced to an epoxy backbone to reduce strength or stiffness of the coating, improve flexibility9Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOand adhesion durability after exposure to humidity and corrosion promoted by salt solutions due to hydrophobicity of the adduct. The diacid component of the epoxy / diacid adduct may be C8-C40 or more, diacid compound that is adducted with an epoxy. The epoxy component of the epoxy / diacid adduct may be DGEBF (diglycidyl ether of bisphenol F) and DGEBA (diglycidyl ether of bisphenol A). The diacids may be saturated or unsaturated. Preferably, the diacid is derived from an unsaturated fatty acid. An example of a preferred epoxy / diacid adduct is the product of the esterification of Epotec® YDF-172LV (DGEBF) and a C18 diacid. Other examples of a preferred epoxy / diacid adduct are HyPox® DA323 (DGEBA and dimer fatty acid adduct) available from Emerald Performance Materials® and Epokukdo YD-172 by Kukdo Chemical Co., Ltd.

[0071] The epoxy / diacid adduct generally includes about 1:6 to 6:1 parts of diacid to epoxy and more preferably about 1:4 to 4:1 parts of diacid to epoxy. More typically, the epoxy / diacid adduct includes at least about 10%, more typically at least about 20% and even more typically at least about 40% by weight diacid and typically includes not greater than about 60% by weight diacid, although higher or lower percentages are possible.

[0072] Generally, it is preferable for the side A to include at least one type of polymeric particle. Such polymeric particles may be utilized to improve fracture toughness (G1C), peel resistance, and impact resistance. As used herein, the term “polymeric particle” is defined as a particle comprising a polymeric material and provides the aforementioned fracture toughness (G1C), peel resistance, and / or impact resistance. Like with any other ingredients of the present teachings, the term “polymeric particle” can include one or more polymeric particles. Various polymeric particles may be employed in the practice of the present teachings and often include one or more elastomers. It is generally preferable for the polymeric particles to be at least 4%, more typically at least 7%, even more typically at least 10%, still more typically at least 13% and even still more typically at least 16% by weight of the side A and also preferable for the polymeric particle to be less than 90%, more typically less than 40% an even more typically less than 30% by weight of the side A, although higher or lower amounts may be used in particular embodiments.

[0073] Examples of useful polymeric particles include but are not limited to particles suspended in liquid epoxy resins, such as those sold under the tradename, Kane Ace™, commercially available from Kaneka Americas Holding, Inc. Particularly preferred grades of Kane Ace™ are10Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOsold under the designations MX-134 and MX-267. The largest dimension of the polymeric particles may average no less than 50 nm and no greater than 300 nm in size.

[0074] It is contemplated that nearly any additional chemicals, materials, or otherwise, may be added to the material assuming they are suitable for the material and suitable for a chosen application of the material.

[0075] The specific combination and relative amounts of one or more materials described herein, may assist in providing improved corrosion resistance.

[0076] Certain coating materials formed in accordance with the present teachings have exhibited excellent adhesion to aluminum and corrosion resistant to highly caustic medium like 6 N sodium hydroxide at 50 °C.

[0077] To evaluate the corrosion resistance, the side and top of aluminum plates are coated with exemplary and comparative two-part coating compositions (see Figure 1A), which are allowed to cure at room temperature for 7 days before being exposed to 6N sodium hydroxide. The bottom of the plates is the only surface where aluminum is in direct contact with the highly caustic medium. In a desirable scenario (see Figure 1B), the coating allows for controlled erosion caused by the caustic medium. Aluminum erosion from the bottom consequently leads to the even thickness reduction of the aluminum plates. Additionally, these coatings exhibit no delamination or blistering before all aluminum is consumed. Erosion that originates from the edge due to the caustic solution’s undercutting between the coating and aluminum (see Figure 1C) is undesirable.

[0078] For exemplary purposes, table A is produced below to illustrate example formulations for forming the room temperature cure coatings.

[0079] Table A1 2 3 4 5 6 7Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOPart BPart B Part B Part B Part B Part B Part B(%)(%) (%) (%) (%) (%) (%) Polyamide curative 1 95.97 95.97 95.97 95.97 95.97 0.00 42.78 Polyamide curative 2 76.78 Wollastonite 0.00 0.00 0.00 0.00 0.00 19.19 53.48 Fumed silica 3.84 3.84 3.84 3.84 3.84 3.84 3.57 pigment (yellow) 0.19 0.19 0.19 0.19 0.19 0.19 0.17 total 100 100 100 100 100 100 100[0080xamples shown in Tableand Figure 2 demonstratechange in chemical resistant properties against 6N NaOH based upon the inclusion / removal of certain components in the material disclosed herein. Of note, when a certain ingredient is removed, the amount of other ingredients is adjusted to keep the same stoichiometric ratio. Samples 1 and 6 include all components displayed in Table A and demonstrate the highest resistance. After 24h immersion, there is no undercutting between the coating and aluminum (Figure 2A, B and G) and aluminum erosion is only from the bottom (as illustrated in Figure 1B). Samples 2 to 5 with removal of phenoxy resin, liquid elastomer adduct, polysulfide adduct, and silane modified epoxy resin all show a gap between the aluminum and the coating indicating undesirable erosion of aluminum from the edge (as illustrated in Figure 1C). Sample 7 is a formulation with only liquid epoxy resin in part A and also showed delamination and erosion from the edge. Inspection of these results reveals the synergistic effect of combining various components such as phenoxy resin, liquid elastomer adduct, polysulfide adduct and silane-modified epoxy resin in improving resistance to 6N NaOH.

[0081] Samples 1 and 6 with all ingredients in epoxy resin composition A show superior resistance to these media, while the polyamide curative 2 in sample 6 results in some loss of hardness after exposure to acids. Phenoxy resin is known to exhibit improved chemical resistance. Removal of phenoxy resin (sample 2) leads to over 20% loss of hardness against 6N KOH, glycol, ethanol, and HCl. Similarly, it is not surprising that exclusion of polysulfide adduct in sample 4 leads to approximately 20% loss against acids due to its well-known chemical resistance.

[0082] Liquid elastomer and its adducts have been widely used in epoxy based formulations for toughening. It is interesting that the present teachings also demonstrate its important role in chemical resistance. Sample 3 without liquid elastomer adduct shows above 10% loss of hardness against organic solvents. In contrast, silane-modified epoxy resin is not as crucial to maintain the12Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOhardness after exposure to the evaluated media. However, it contributes to improved adhesion to various substrates for coating durability. Clearly, the coating compositions with a combination of phenoxy resin, liquid elastomer adduct, and polysulfide adduct demonstrate superior chemical resistance against strong bases, acids, and certain organic solvents.

[0083] In addition to 6N NaOH, chemical resistance to other common acids, bases, and organic solvents is also evaluated by measuring the loss of coating hardness after exposure to these media (Table 2).

[0084] Table 2. Chemical resistance to other common acids, bases, and organic solvents Shore DhardnessSample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6s)s)s)s) ss)s)

[0085] Samples 1 and 6 show superior resistance to these media, while polyamide curative 2 in sample 6 results in some loss of hardness after exposure to acids. Phenoxy resin may provide chemical resistance. Removal of phenoxy resin (sample 2) leads to over 20% loss of hardness against 6N KOH, glycol, ethanol, and HCl. Similarly, exclusion of polysulfide adduct in sample 4 leads to approximately 20% loss against acids.

[0086] Liquid elastomer and its adducts have been widely used in epoxy based formulations for toughening. It is unexpected and interesting that the present teachings also demonstrate its important role in chemical resistance. Sample 3 without liquid elastomer adduct shows above 10% loss of hardness against organic solvents. In contrast, silane-modified epoxy resin is not as crucial13Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOto maintain the hardness after exposure to the evaluated media. However, it contributes to improved adhesion to various substrates for coating durability. Clearly, the coating compositions with a combination of phenoxy resin, liquid elastomer adduct, and polysulfide adduct demonstrate superior chemical resistance against strong bases, acids, and certain organic solvents.

[0087] Table 3. exemplary formulations for durable, impact resistant coatings against hostile mediaIngredient (%) Sample 8 Sample 9Part A14Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WO

[0088] Table 3 shows two examples of durable and impact resistant coatings with excellent chemical resistance to hostile media. Both coatings showed excellent resistance to 2.5% ammonia, Manure, Xylene, and 5% sodium hydroxide. After 7d exposure to these media, there is no noticeable difference compared to coatings prior to exposure.

[0089] As used herein, unless otherwise stated, the teachings envision that any member of a genus (list) may be excluded from the genus; and / or any member of a Markush grouping may be excluded from the grouping.

[0090] Unless otherwise stated, any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component, a property, or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that intermediate range values such as (for example, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. As can be seen, the teaching of amounts expressed as "parts by weight" herein also contemplates the same ranges expressed in terms of percent by weight. Thus, an expression in the of a range in terms of at "'x' parts by weight of the resulting polymeric blend composition" also contemplates a teaching of ranges of same recited amount of "x" in percent by weight of the resulting polymeric blend composition."

[0091] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0092] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and15Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOnovel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist of, or consist essentially of the elements, ingredients, components or steps.

[0093] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0094] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.16

Claims

Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WOCLAIMS WHAT IS CLAIMED IS:

1. A two-part coating comprising:a part A including an epoxy resin composition comprising a phenoxy resin;a part B including at least one room temperature curative composition;wherein the part A includes an amine terminated elastomer modified epoxy and / or thiol terminated elastomer modified epoxy and / or the Part B includes an amine terminated elastomer and / or thiol terminated elastomer.

2. The two-part coating of claim 1, wherein the part A includes a silane-modified epoxy resin in the range of about 0.5% to about 70% by weight of the part A.

3. The two-part coating of claim 1 or claim 2, wherein the phenoxy resin is present in an amount of from 0.5% to 20% by weight of the part A.

4. The two-part coating of any of the preceding claims, wherein the part A includes an elastomer / epoxy adduct in the range of from 1% to 60% by weight of the part A.

5. The two-part coating of any of the preceding claims, wherein the part B includes at least one multifunctional room temperature curative in the range of 0.5% to 97% by weight of the part B.

6. The two-part coating of any of the preceding claims, wherein the part B comprises an amine or thiol-terminated elastomer in the range of about 2% to 40% by weight of the part B.

7. The two-part coating of any of the preceding claims, wherein the part B comprises a difunctional chain extender in the range of about 0.5% to about 30% by weight of the part B.17Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WO8. The two-part coating of any of the preceding claims, including an epoxy / diacid adduct present in an amount of from about 0.2% to about 25% by weight, or even from about 6% to about 10% by weight of the part A.

9. The two-part coating of any of the preceding claims, including a polymeric particle present in an amount of at least about 3% but less than about 60% by weight, or even at least about 10% but less than about 32% by weight of the part A.

9. The two-part coating of any of the preceding claims, comprising a flexibilizer in the range of about 2% to about 50% by weight of the part A and / or the part B.

10. The two-part coating of any of the preceding claims, wherein the room temperature curative composition is selected from the group consisting of an amine, an amine derivative, a polyamide, a mercaptan, a mercaptan derivative or any combination thereof.

11. The two-part coating of claim 4, wherein the elastomer in the epoxy / elastomer adduct is selected from the group consisting of amine-terminated butadiene-acrylonitrile (ATBN), carboxyl-terminated butadiene-acrylonitrile (CTBN), epoxy-terminated butadiene-acrylonitrile (ETBN), di or multi-mercaptan, polysulfide, or combinations thereof.

12. The two-part coating of any of the preceding claims, including a difunctional chain extender selected from selected from 1-naphthylamine, 2-naphthylamine, ethanolamine, phenethylamine, oleylamine, dimercaptans (e.g., 2,2′-(ethylenedioxy)diethanethiol and 1,2-ethanedithiol), or any combination thereof.

13. The two-part coating of any of the preceding claims, including an epoxy / diacid adduct wherein the diacid component is selected from a C18 diacid, a C36 diacid, or any combination thereof.18Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WO14. The two-part coating of any of the preceding claims, comprising a flexibilizer wherein the flexibilizer is a stand-alone component or is adducted with epoxy and is selected from, phenol terminated urethane, Epoxonic 328 or any combination thereof.

15. The two-part coating of claim 9, wherein the polymeric particle includes core modifiers of polybutadiene, styrene-butadiene rubber, or a combination thereof.

16. The two-part coating of claim 9, wherein the polymeric particle includes core / shell rubber particles averaging about 100-200 nm in size.

17. The two-part coating of any of claim 9, wherein the polymeric particle is substantially free of agglomerated particles.

18. The two-part coating of claim 1, including one or more fillers or fibers.

19. The two-part coating of claim 18, wherein the one or more fillers or fibers are selected from the group consisting of silica, diatomaceous earth, glass, clay, glass beads or bubbles, glass, carbon or ceramic fibers, nylon, aramid or polyamide fibers, pyrophyllite, sauconite, saponite, nontronite, wollastonite, and montmorillonite and combinations thereof.

20. The two-part coating of claim 18, including a silica and / or calcium-based filler.

21. The two-part coating of claim 20, wherein the silica-based filler is fumed silica.

22. The two-part coating of any of the preceding claims, wherein the ratio of part A to part B is about 2:1.

23. The two-part coating of any of the preceding claims, wherein the ratio of part A to part B is about 1:1.19Filed via USPTO on September 29, 2025Attorney Docket No.: 1001.926WO24. The two-part coating of any of the preceding claims, wherein part A includes a polysulfide adduct and a silane-modified epoxy.

25. The two-part coating of any of the preceding claims, wherein part A includes a liquid elastomer adduct and the phenoxy resin and the thiol terminated elastomer modified epoxy are present in a ratio of from about 2:1 to about 1:2.

26. A two-part coating comprising:a part A including an epoxy resin composition comprising phenoxy resin;a Part B including a curative composition adapted to cure the two-part coating at room temperature;wherein the part A includes an amine terminated elastomer modified epoxy and a thiol terminated elastomer modified epoxy.

27. The two-part coating of claim 26, wherein the part A includes a silane-modified epoxy resin in the range of about 0.5% to about 70% by weight of the part A.

28. A two-part coating comprising:a part A including an epoxy resin composition comprising phenoxy resin;a part B including at a curative composition adapted to cure the two-part coating at room temperature;wherein the part B includes an amine terminated elastomer and a thiol terminated elastomer.

29. The two-part coating of claim 28, wherein the part A includes a silane-modified epoxy resin in the range of about 0.5% to about 70% by weight of the part A.

30. The two-part coating of any of the preceding claims, wherein the coating is substantially free of any component requiring heat for curing.20

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