Single-pack water-based self-primer coating composition for metallic and non-metallic structures

Abstract

The present invention relates to a single-pack water-based self-primer coating composition that provides enhanced chemical resistance, corrosion protection, and fire resistance for metallic and non-metallic surfaces The composition comprises 70-75 % w / w of hybrid resin; 4-5 % w / w of zinc phosphate; 15-25 % w / w of rutile; 5-10 % w / v of de-mineralized water; 0.05-0.15 % w / w of de-foamer; 0.05-0.15 % w / w of thixotropic agent; 0.05-0.15 % w / w of anti-fouling agent; and 0.5 to 1.0 % of paste forming agent, wherein the paste forming agent consisting of 90-95 % w / v of D.M. Water, and 5-10 % w / w of carbon nanoparticle. The composition is VOC-free, environmentally safe, and provides a durable, high-performance solution that simplifies the application process, eliminating the need for additional primer layers. Additionally, the coating composition exhibits fire resistance by forming a stable insulating layer (char), limiting oxygen supply, and dissipating heat under extreme conditions.

Description

[0001] “SINGLE-PACK WATER-BASED SELF-PRIMER COATING COMPOSITION FOR METALLIC AND NON-METALLIC STRUCTURES”

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to the field of protective coatings, specifically to water-based chemical-resistant anti-corrosive paints. More particularly, the present invention discloses a single pack, self-primer coating composition for the protection of metallic structures like Iron, Copper, Zinc, and Aluminum, and non-metallic structures like plastic or glass that provides enhanced corrosion resistance, chemical durability, fire resistance, and environmental sustainability.

[0004] BACKGROUND OF THE INVENTION

[0005] Protective coatings play a critical role in extending the lifespan and maintaining the performance of structures and equipment subjected to corrosive environments. These coatings are particularly essential in industrial, marine, and infrastructure applications where exposure to harsh chemicals, extreme temperatures, and environmental conditions can severely compromise materials. Traditionally, solvent-based anti-corrosive coatings, such as two-pack epoxy systems, have been the preferred choice due to their exceptional durability, chemical resistance, and mechanical toughness.

[0006] While effective, solvent-based coatings present significant drawbacks. Such as, the two-pack epoxy systems require precise mixing of epoxy resin and hardener immediately before application, which complicates the process and increases labour demands. Additionally, these coatings are sensitive to environmental factors like temperature and humidity, potentially affecting curing and performance. Perhaps most critically, solvent-based paints emit high levels of volatile organic compounds (VOCs), contributing to air pollution and posing health and safety risks to applicators. These issues, combined with limited pot life and associated material waste, lead to increased costs and inefficiencies.

[0007] As concerns about environmental degradation grow, international regulations aimed at reducing VOC emissions have become stricter, prompting industries to seek sustainable alternatives. In this context, water-based paints have emerged as an environmentally friendly solution, using water as a medium instead of organic solvents. Water-based paints offer several advantages, including significantly reduced VOC emissions, improved safety for workers, and enhanced ease of use. Moreover, they eliminate strong odours and are easier to clean, making them more user- friendly and eco-conscious.

[0008] Water-based paints have gained popularity across a range of applications, from automotive and industrial painting to protective coatings for infrastructure. Among these, water-based metallic undercoats are particularly advantageous, offering not only environmental benefits but also improved cost-performance and superior finished appearance. Despite these benefits, the transition to water-based systems has faced challenges, particularly in industrial applications requiring high durability and chemical resistance.

[0009] Existing water-based coatings often require separate primer layers to achieve adequate adhesion and corrosion resistance, adding complexity and cost to the application process. Additionally, these coatings sometimes lack the durability, chemical resistance, and UV protection provided by solvent-based systems. Hence, there is a need in prior art for a simplified yet high- performance solution in water-based paint technology.

[0010] Therefore, to address the limitations associated with prior art water based paint composition. The present invention discloses a single-pack water-based self-primer coating composition. This advanced formulation eliminates the need for separate primers thus simplify the application and reduce costs.

[0011] The present invention unique single-pack coating composition aligns with global sustainability goals by being VOC-free and environmentally friendly. It not only simplifies the coating process but also ensures long-term durability and cost-performance, making it an ideal choice for industries such as automotive, marine, industrial manufacturing, and infrastructure.

[0012] OBJECTIVES OF THE INVENTION

[0013] Some of the objects of the present disclosure aimed to mitigate one or more problems of the prior art or to at least provide a useful alternative is described herein below:

[0014] The primary objective of the present invention is to provide a single-pack water-based selfprimer coating composition having high chemical resistance, corrosion protection, and fire resistance for metallic and non-metallic surfaces.

[0015] Another objective of the present invention is to provide a single-pack water-based self-primer coating composition for metal structures, civil structures, battery manufacturing units, acid manufacturing units, chemical manufacturing units, high chlorides areas, coastal area coating cement and other substrate protective coating and coil coating for fridge, automotive etc.

[0016] Yet another objective of the present invention is to provide a single-pack system that eliminates the need for complex mixing and storage requirements associated with two-pack systems, simplifying handling and reducing errors.

[0017] Yet another objective of the present invention is to provide VOC-free, eco-friendly coating composition that aligns with international environmental regulations and reduces the pollution associated with solvent-based paints.

[0018] Yet another objective of the present invention to provide a coating composition compatible with various application methods such as spraying, rolling, and brushing, making it suitable for diverse industrial and commercial environments.

[0019] Yet another objective of the present invention to coating composition with fast -curing time of 10-15 minutes thus reduces downtime and enhances productivity in industrial settings.

[0020] Yet another objective of the present invention to eliminate the need for a separate primer layer to simplify the application process, reduces labour and material costs, and improves efficiency.

[0021] Yet another objective of the present invention to integrate fire-resistant properties into the coating composition, making it ideal for use in environments where fire hazards are a concern, such as chemical plants and oil refineries.

[0022] Further objectives, advantages, and features of the present invention will become apparent from the detailed description provided herein below, in which various features and functionalities of the disclosed invention are illustrated by way of the following examples.

[0023] SUMMARY OF THE PRESENT INVENTION

[0024] The present invention discloses a novel single-pack water-based self-primer coating composition designed to provide improved chemical resistance, corrosion protection, and fire resistance for metallic and non-metallic surfaces. The disclosed composition addresses the limitations of traditional solvent-based and water-based paints by offering an eco-friendly, high-performance solution that simplifies application while ensuring durability and sustainability.

[0025] According to another embodiment of the present invention, the single-pack water-based self- primer coating composition comprises: 70-75 % w / w of hybrid resin; 4-5 % w / w of zinc phosphate; 15-25 % w / w of rutile; 5-10 % w / v of de-mineralized water; 0.05-0.15 % w / w of defoamer; 0.05-0.15 % w / w of thixotropic agent; 0.05-0.15 % w / w of anti-fouling agent; and 0.5 to 1.0 % of paste forming agent,

[0026] Wherein the paste forming agent consisting of 90-95 % w / v of D.M. Water, and 5-10 % w / w of carbon nanoparticle.

[0027] The single pack design of the paint composition eliminates the need or mixing separate components, as required in traditional two-pack systems, and serves as a self-primer. This innovation reduces the need for additional primer layers, streamlining the application process and lowering costs.

[0028] In another embodiment, the present invention discloses a method for preparing the water-based anti-corrosive paint composition; the method comprises the steps of: mixing all the ingredients including hybrid resins, paste forming agents, and other additives in a bead mill under controlled cooled conditions; adding corrosion-resistant pigments, including zinc phosphate and carbon nanoparticles, to the mixture to enhance the chemical and mechanical properties; and adjusting the viscosity and solid content of the batch to desired levels using de-ionized water as a solvent.

[0029] After mixing, the resulting batch of the prepared single pack paint composition undergoes Gauge testing, specifically Hegmang Gauge testing. A sample from the bead mill is taken and placed on the Hegmang Gauge. If the reading is more than 5 gauges, the batch undergoes further dispersion. If the reading is less than 5 gauges, the batch qualifies for the next step of unloading. The batch is then unloaded to the mixing vessel, where carbon paste is added. The viscosity of the final paint is adjusted to 60-65 sec before the Ford cup, and the solids content is adjusted to NV 60-65%. The paint composition is then cooled and packed for commercial use.

[0030] Single-pack water-based self-primer paint composition and its preparation method thereof according to a preferred embodiment of the present invention is herein described in the following description and illustrated in the accompanying example.

[0031] BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Fig. 1 illustrates a comparison table to provide the technical difference between the conventional paint solution and the single pack water based self-primer coating composition of the present invention. Fig. 2 illustrates tabulated results to show the performance results of water-based (WB), solvent-based (SB), and traditional water-based paint compositions subjected to chemical resistance testing for duration of 72 hours, according to an exemplary embodiment of the present invention.

[0033] Fig. 3 illustrates tabulated results to show the performance results of water-based (WB), solvent-based (SB), and traditional water-based paint compositions subjected to chemical resistance testing for duration of 5 days, according to an exemplary embodiment of the present invention.

[0034] DETAILED DESCRIPTION OF THE INVENTION

[0035] Single-pack water-based self-primer paint composition and a process for the preparation thereof are herein described with numerous specific details to provide a complete understanding of the invention. However, these specific details are exemplary details and should not be treated as a limitation to the scope of the invention.

[0036] Throughout this specification, the word “comprises” or variations such as “comprises or comprising”, will be understood to imply the inclusions of a stated element, integers or step, or group of elements, integers, or steps, but not the exclusions of any other element, integer or step, or group of elements, integers, or steps.

[0037] The present invention relates to a single-pack water-based self-primer coating composition that offers superior chemical resistance, corrosion protection, and fire resistance. This innovative composition is designed for use on metallic and non-metallic surfaces, addressing the limitations of traditional solvent-based and two-pack water-based systems.

[0038] In the preferred embodiment of the present invention, the single pack self-primer water-based coating composition comprises: 70-75 % w / w of hybrid resin; 4-5 % w / w of zinc phosphate; 15-25 % w / w of rutile; 5-10 % w / v of de -mineralized water; 0.05-0.15 % w / w of de-foamer; 0.05-0.15 % w / w of thixotropic agent; 0.05-0.15 % w / w of anti-fouling agent; and 0.5 to 1.0 % of paste forming agent,

[0039] Wherein the paste forming agent consisting of 90-95 % w / v of D.M. Water, and 5-10 % w / w of carbon nanoparticle. According to another embodiment of the present invention, the water-based hybrid resin is selected from the group consisting of acrylic resins, epoxy resins, polyurethane resins, and polyester resins.

[0040] According to another embodiment of the present invention, the carbon nanoparticles are selected from the group consisting of carbon nanotubes, graphene, and activated carbon.

[0041] According to another embodiment of the present invention, the wetting agent is selected from the group consisting of non-ionic surfactants, anionic surfactants, or cationic surfactants, to improve the spread ability and uniformity of the coating.

[0042] According to another embodiment of the present invention, the defoamer is selected from the group consisting of silicone -based defoamers, polyether-based defoamers, or organic ester defoamers to reduce the formation of bubbles during application.

[0043] According to another embodiment of the present invention, the thixotropic agent is selected from the group consisting of fumed silica, bentonite, or organic thixotropic agents, to adjust the viscosity and flow characteristics of the composition.

[0044] According to another embodiment of the present invention, wherein the anti-fouling Agent is selected from the group consisting of copper-based compounds, zinc -based compounds, or organotin compounds, to prevent microbial growth on the coated surface.

[0045] According to another embodiment of the present invention, the formulated paint composition exhibits fire resistance property which enhance paint’s safety in industrial, marine, and infrastructural applications. The coating provides a protective barrier that resists ignition, flame propagation, and heat transfer when exposed to high temperatures or fire hazards.

[0046] According to another embodiment of the present invention, the mechanism of fire resistance in the coating composition is based on a multi-faceted approach. First, the hybrid resin and carbon nanoparticles work together to form a stable insulating layer, or char, under extreme heat. This layer acts as a protective barrier, shielding the substrate from direct exposure to flames. Second, the formulation plays a crucial role in oxygen suppression by creating a barrier that limits the oxygen supply, a key factor in slowing the spread of combustion. Lastly, the material's composition includes thermally stable components that resist heat buildup, preventing the ignition of the coated surface and further enhancing its fire-resistant properties. Together, these mechanisms provide an effective protection against fire hazards, ensuring the safety and durability of the material.

[0047] In another embodiment, the present invention discloses a method for preparing the water-based self-primer paint composition; the method comprises the steps of: mixing all the ingredients including hybrid resins, paste formation, and additives in a bead mill under controlled cooled conditions; adding corrosion-resistant pigments, including zinc phosphate and carbon nanoparticles, to the mixture to enhance the chemical and mechanical properties; and adjusting the viscosity and solid content of the batch to desired levels using de-ionized water as a solvent.

[0048] After mixing, the resulting batch of the anti-corrosive paint composition undergoes Gauge testing, specifically Hegmang Gauge testing. A sample from the bead mill is taken and placed on the Hegmang Gauge. If the reading is more than 5 gauges, the batch undergoes further dispersion. If the reading is less than 5 gauges, the batch qualifies for the next step of unloading. The batch is then unloaded to the mixing vessel, where carbon paste is added. The viscosity of the final paint is adjusted to 60-65 sec before the Ford cup, and the solids content is adjusted to NV 60-65%. The paint composition is then cooled and packed for commercial use.

[0049] According to another embodiment of the present invention, the single pack self-primer water based composition has application in several industries including but not limited to petroleum, steel, picking line, paper, ship building, railways, coastal areas, power transmission and other sectors.

[0050] EXAMPLE

[0051] The following example is put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the methods and systems claimed herein are performed and evaluated and are intended to be purely exemplary of the invention and are not intended to limit the scope of what the inventor regards as their invention.

[0052] The quantities of ingredients present in self-primer water based paint composition are expressed in per cent by weight with respect to the total weight.

[0053] Wherein, the paste forming agent includes

[0054] The present invention is not limited to a specific formulation or application and can be customized to suit different industrial requirements by varying the composition or method of preparation. For example: Different additives may be added to composition for enhanced fire resistance, anti-static properties, or flexibility in extreme conditions.

[0055] Moreover, the formulation can be adjusted to include additional UV stabilizers, color pigments, or surface-active agents to meet specific user requirements. The paint can be optimized for niche applications such as coil coating for refrigeration units, automotive components, or specialized marine coatings.

Claims

CLAIMSWe claim,1. A single-pack water-based self-primer coating composition, comprising: a. 70-75% by weight of a hybrid resin to form the base matrix; b. 4-5% by weight of zinc phosphate to provide adhesion and corrosion resistance; c. 15-25% by weight of rutile as an extender pigment for durability and opacity; d. 5-10% by volume of de -mineralized water as a solvent; e. 0.05-0.15% by weight of a defoamer to minimize bubble formation during application; f. 0.05-0.15% by weight of a thixotropic agent to control viscosity and flow properties; g. 0.05-0.15% by weight of an anti-fouling agent to inhibit microbial growth on the coated surface; and h. 0.5-1.0% by weight of a paste-forming agent, wherein the paste-forming agent consisting of: 90-95% by volume of de-mineralized water, and 5-10% by weight of carbon nanoparticles to impart anti-static and chemicalresistant properties.

2. The composition as claimed in claim 1, wherein the water-based hybrid resin is selected from the group consisting of acrylic resins, epoxy resins, polyurethane resins, and polyester resins.

3. The composition as claimed in claim 1, wherein the carbon nanoparticles are selected from the group consisting of carbon nanotubes, graphene, and activated carbon.

4. The composition as claimed in claim 1, wherein the wetting agent is selected from the group consisting of non-ionic surfactants, anionic surfactants, or cationic surfactants, to improve the spreadability and uniformity of the coating.

5. The composition as claimed in claim 1, wherein the defoamer is selected from the group consisting of silicone-based defoamers, polyether-based defoamers, or organic ester defoamers to reduce the formation of bubbles during application.

6. The composition as claimed in claim 1, wherein the thixotropic agent is selected from the group consisting of fumed silica, bentonite, or organic thixotropic agents, to adjust the viscosity and flow characteristics of the composition.

7. The composition as claimed in claim 1, wherein the anti-fouling Agent is selected from the group consisting of copper-based compounds, zinc -based compounds, or organotin compounds, to prevent microbial growth on the coated surface.

8. The composition as claimed in claim 1, wherein the self-primer coating composition exhibits fire resistance properties due to the formation of a stable insulating layer (char) under extreme heat, oxygen suppression, and heat dissipation, preventing ignition and slowing the spread of flames.

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