Gloss and matte biobased protective coating system

Abstract

A two-component aliphatic polyurethane system for preparation of coatings, a coating made therefrom, and methods of making the same. The coating system contains component (A) a hydroxyl-containing compound and component (B) an aliphatic isocyanate and / or a cycloaliphatic isocyanate. The coating composition of the present invention is water-based and free from volatile organic compounds. The coating composition also may be composed of one or more bio-based material totaling from 15 wt% to 95 wt% and may have high solids of over 60% after component A and B are mixed, which can then be reduced with water up to 50%

Description

[0001] Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0002] TITLE OF THE INVENTION GLOSS AND MATTE BIOBASED PROTECTIVE COATING SYSTEM

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] The present application claims priority to U. S. Provisional Appl. No. 63 / 730,319, filed December 10, 2024, the entire contents of which are incorporated herein by reference.

[0005] FIELD OF THE INVENTION

[0006] The present invention provides a two-component aliphatic polyurethane system for preparation of coatings, a coating made therefrom, and methods of making the same. The coating system contains component (A) a hydroxyl-containing compound and component (B) an aliphatic isocyanate and / or a cycloaliphatic isocyanate. The coating composition of the present invention is water-based and free from volatile organic compounds (‘’VOC”). The coating composition also may be composed of one or more bio-based material totaling from 15 wt% to 95 wt% and may have high solids of over 60% after component A and B are mixed, which can then be reduced with water up to 50%.

[0007] DISCUSSION OF THE BACKGROUND

[0008] Even’ day people are surrounding and exposed to toxic glues and coatings.

[0009] Conventional polyurethane based systems may be formed by reacting an isocyanate compound with a polyol compound, of which the polyol used may have at least one petroleum-based building block (such as ethylene oxide and / or propylene oxide). While such petrochemical based polyols are widely used, these polyols face many problems in addition to the health drawbacks, such as exhaustion of natural resources and fluctuations in price based on changes in oil price. Although bio-based oils may seem to be an attractive alternative. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0010] most bio-based oils are not miscible in water and therefore these alternatives typically contain volatile organic compounds and / or strong off-gassing odors.

[0011] In view of the foregoing, there remains a critical need in the art to develop safe and effective coatings.

[0012] SUMMARY OF THE INVENTION

[0013] It is an object of the present invention to provide a water-based two-component aliphatic polyurethane system that provides having excellent adhesion, excellent durability,, and excellent corrosion, chemical and acid resistance, while having no VOCs or odor and is easy to apply, dries at ambient temperatures within 8 hours or less and easy to clean up with water.

[0014] The coating system contains component (A) a hydroxyl-containing compound and component (B) an aliphatic isocyanate and / or a cycloaliphatic isocyanate. The coating composition of the present invention is water-based and free from volatile organic compounds (;‘VOC”) including formaldehyde.

[0015] A kit containing, separately packaged component (A) and component (B) together with instructions for use thereof, wherein component (A) comprises a hydroxyl-containing compound and component (B) comprises an aliphatic isocyanate and / or a cycloaliphatic isocyanate, and wherein component (A) and component (B) are water-based and free from volatile organic compounds.

[0016] A method of making a coating composition, by

[0017] (1) Stirring, shaking, or agitating a component (A) comprising a hydroxyl-containing compound for a time and under conditions to fully disperse the hydroxyl-containing compound and component; Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0018] (2) Adding a component (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate, which has been optionally stirred, shaken, or agitated for a time and under conditions to fully disperse the aliphatic isocyanate and / or cycloaliphatic isocyanate; and

[0019] (3) Mixing components (A) and (B) for a time sufficient to substantially blend components (A) and (B) to form a coating composition.

[0020] A method of coating a surface of a material with a coating composition, comprising: applying a coating composition prepared by the foregoing method to the surface of many different materials including ceramic, glass, concrete, wood, metal (including aluminum), galvanized & ungalvanized steel, tile, and textiles and allowing the coating composition to cure.

[0021] A coated material, wherein said material has a coating thereon wherein the coating comprises the reaction product of a component (A) comprising a hydroxyl-containing compound and a component (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate, wherein the coating contains no VOCs and has at least 15 wt% of a bio-based (e.g., plant-based and / or bio-renewable polymer).

[0022] The above objects highlight certain aspects of the invention. Additional objects, aspects and embodiments of the invention are found in the following detailed description of the invention.

[0023] BRIEF DESCRIPTION OF THE FIGURES

[0024] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following Figures in conjunction with the detailed description below. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0025] Fig. 1 shows a tile and wood samples coated with a coating composition of the present invention.

[0026] Fig. 2 shows aluminum samples coated with a coating composition of the present invention, which was subjected to MEK5000, MEK6000, and MEK8000.

[0027] DETAILED DESCRIPTION OF THE INVENTION

[0028] Unless specifically defined, all technical and scientific terms used herein have the same meaning as commonly understood by a skilled artisan in chemistry (e.g., polyurethane chemistry), coatings, and adhesives.

[0029] All methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, with suitable methods and materials being described herein. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. Further, the materials, methods, and examples are illustrative only and are not intended to be limiting, unless otherwise specified.

[0030] Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.

[0031] The present invention provides a coating system containing component (A) comprising a hydroxyl-containing compound and component (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate. The coating composition of the present invention is water-based and free from volatile organic compounds (“VOC”) including formaldehyde. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0032] In an embodiment, components (A) and (B) are present in the coating composition at a weight ratio of (A): (B) of at least 0.5:1, at least 0.6:1, at least 0.7:1, at least 0.8:1, at least 0.9:1, at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.3: 1, at least 1.4:1, at least 1.5:1, at least 1.6:1, at least 1.7:1, at least 1.8: 1, at least 1.9:1, or at least 2:1. The coating composition has a weight ratio of components (A) and (B) of (A): (B) of at most 3: 1, at most 2.9:1, at most 2.8:1, at most 2.7:1, at most 2.6:1, at most 2.5:1, at most 2.4:1, at most 2.3:1, at most 2.2:1, at most 2.1:1, at most 2:1, at most 1.9:1, at most 1.8:1, at most 1.7:1, at most 1.6:1, or at most 1.5:1. In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include from 0.5:1 to 3:1, from 0.5:1 to 2.5:1, from 0.5:1 to 2:1, from 0.5:1 to 1.5:1, from 1:1 to 3:1, from 1:1 to 2.5:1, from 1:1 to 2:1, from 1:1 to 1.5:1, from 1.5:1 to 3:1, from 1.5:1 to 2.5:1, from 1.5:1 to 2:1, from 1.2:1 to 2.8:1, from 1.4:1 to 2.6:1, from 1.5:1 to 2.5:1, from 1.6:1 to 2.4: 1, from 1.8:1 to 2.2:1, from 1.2:1 to 1.8:1, or from 1.2:1 to 1.6:1.

[0033] Component (A)

[0034] Component (A) contains a hydroxyl-containing compound.

[0035] In an embodiment, component (A) is free from (i.e., has zero) VOCs.

[0036] In an embodiment, component (A) is water-based (i.e., is contained in water as a solvent).

[0037] In an embodiment, component (A) is free from organic solvents.

[0038] In an embodiment, the hydroxyl-containing compound is a plant-based compound comprising hydroxyl groups.

[0039] In an embodiment, the plant-based compound comprising hydroxyl groups is a cashew nutshell liquid (CNSL)-derived polyol. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0040] In an embodiment, the plant-based compound comprising hydroxyl groups is a cardanol compound. Cardanol provides several advantages including fast curing, low temperature, adhesion, surfactant effect, thermal and fire resistance, chemical resistance, water resistance, flexibility, low viscosity, surface tension, and wetting properties.

[0041] Cardanol has a general structure of formula (I):

[0042]

[0043] wherein R1is — C15H25, — C15H27, — C15H29. or — C15H31. Specific examples of R1include:

[0044]

[0045] It is understood that within the scope of the present invention the cardanol compound may be a blend of one of more of the foregoing compounds of formula (I).

[0046] Exemplary cardanol compounds include cardanol compounds of formulae (II) - (V): Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0047] (II) OH

[0048] (III)

[0049] (IV)

[0050] (V)

[0051]

[0052] Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0053] In an embodiment of the present invention, of the cardanol compounds present, at least 25 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 55 wt%, at least 60 wt%, at least 65 wt%, at least 70 wt%, at least 75 wt%, at least 80 wt%, at least 85 wt%, at least 90 wt%, at least 95 wt%, at least 97.5 wt%, at least 99 wt%, or about 100 wt% is tri-unsaturated cardanol (-C15H25; formula (II)). Alternatively, of the cardanol compounds present, 25 to 65 wt%, 30 to 60 wt%, 35 to 55 wt%, or 40 to 50 wt% is tri-unsaturated cardanol (-C15H25; formula (II)).

[0054] In an embodiment of the present invention, of the cardanol compounds present, 15 to 50 wt%, 20 to 45 wt%, 25 to 40 wt%, or 30 to 35 wt% is mono-unsaturated (-C15H29; formula (IV)).

[0055] In an embodiment of the present invention, of the cardanol compounds present, 5 to 40 wt%, 10 to 35 wt%, 15 to 30 wt%, or 20 to 25 \\1% is bi -unsaturated (-C15H27; formula (III)).

[0056] In an embodiment of the present invention, of the cardanol compounds present, 0 to 10 wt%, 0.5 to 7.5 wt%, 1 to 5 wt%, 2 to 4 wt% is saturated (-C15H31; formula (V)).

[0057] An exemplary formulation of cardanol compounds for use in the present invention includes: tri-unsaturated cardanol (-C15H25; formula (II)), the major component is present at from 35 to 55 wt%, from 25 to 40 wt% mono-unsaturated cardanol (-C15H29; formula (IV)), from 15 to 30 wt% bi-unsaturated cardanol (-C15H27: formula (III)), and 1 to 5% saturated cardanol (-C15H31; formula (V)).

[0058] A specific exemplary formulation of cardanol compounds for use in the present invention includes: tri-unsaturated cardanol (-C15H25; formula (II)), the major component (41%). The remaining cardanol is 34% mono-unsaturated (-C15H29: formula (IV)), 22% biunsaturated (-C15H27; formula (III)), and 2% saturated (-C15H31: formula (V)). Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0059] The cardanol compound may be a by-product of cashew nut processing (e.g., may be extracted from a layer between a nut and a shell of a cashew nut). Within the present invention, the cardanol compound may be used in the form of cashew nutshell liquid.

[0060] Component (A) may further contain cardol, methylcardol, and / or anacardic acid as secondary components.

[0061] Cardol has the general structure of formula (VI):

[0062]

[0063] R1is as defined above.

[0064] Methylcardol has the general structure of formula (VII):

[0065]

[0066] (VII)

[0067] R1is as defined above.

[0068] Anacardic acid has the general structure of formula (VIII):

[0069]

[0070] (VIII):

[0071] R1is as defined above. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0072] In an embodiment, component (A) comprises at least one CNSL-derived polyol and / or card cardanol compound. The component (A) may contain one or more additional polyol compound(s) and / or one or more additives as defined herein below. The additional polyol compound(s) may be any polyol compound, including non-petroleum-derived polyols, glycerol, polyvinyl alcohol, and a polyacrylate or a bio-based, hydroxyl-containing compound as defined herein below.

[0073] In an embodiment, the hydroxyl-containing compound(s) makes up at least at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 52.5 wt%, at least 55.0 wt%, at least 57.5 wt%, at least 60 wt%, at least 62.5 wt%, at least 65 wt%, at least 67.5 wt%, at least 70 wt%, at least 72.5 wt%, or at least 75 wt% of the total composition of component (A). The hydroxyl-containing compound(s) makes up at most 100 wt%, at most 95 wt%, at most 90 wt%, at most 85 wt%, at most 82.5 wt%, at most 80 wt%, at most 77.5 wt%, at most 75 wt%, at most 72.5 wt%, at most 70 wt%, at most 67.5 wt%, at most 65 wt%, at most 62.5 wt%, at most 60 wt%, at most 57.5 wt%, at most 55 wt%, at most 52.5 wt% or at most 50 wt% of the total composition of component (A). In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include 35 wt% to 100 wt%, 45 wt% to 100 wt%, 55 wt% to 100 wt%, 65 wt% to 100 wt%, 35 wt% to 80 wt%, 45 wt% to 80 wt%, 55 wt% to 80 wt%, 65 wt% to 80 wt%, 35 wt% to 75 wt%, 45 wt% to 75 wt%, 50 wt% to 75 wt%, and 55 wt% to 75 wt%.

[0074] In an embodiment, of the hydroxyl-containing compound(s) contained in component (A) at least 40 wt%, at least 45 wt%, at least 50 wt %, at least 55 wt%, at least 60 wt %, at least 65 wt%, at least 70 wt %. at least 75 wt%, at least 80 wt %, at least 90 wt %, or 100 wt % is a cardanol compound and / or a CNSL-derived polyol. Of the hydroxyl-containing compound(s) contained in component (A) at most 100 wt%, at most 95 wt%. at most 90 wt%, Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0075] at most 85 wt%, at most 82.5 wt%, at most 80 wt%, at most 77.5 wt%, at most 75 wt%, at most 72.5 wt%, at most 70 wt%, at most 67.5 wt%, at most 65 wt%, at most 62.5 wt%. at most 60 wt%, at most 57.5 wt%, at most 55 wt%, at most 52.5 wt% or at most 50 wt% is a cardanol compound and / or a CNSL-derived polyol. In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include 40 wt% to 100 wt%, 50 wt% to 100 wt%, 60 wt% to 100 wt%, 70 wt% to 100 wt%, 40 wt% to 80 wt%, 50 wt% to 80 wt%, 60 wt% to 80 wt%, 40 wt% to 75 wt%, 50 wt% to 75 wt%, 60 wt% to 75 wt%, and 50 wt% to 70 wt%.

[0076] Component (A) may include cardanol as a primary component and may additionally include cardol, methylcardol, and / or anacardic acid as secondary components. For example, component (A) may include at least 50 wt % (e.g., at least 60 wt %, at least 70 wt %, at least 80 wt %, at least 90 wt %, and / or 100 wt %) of cardanol; from 20 wt % to 50 wt % (e.g., from 20 wt % to 45 wt %, from 25 wt % to 40 wt %, from 35 wt % to 40 wt %, etc.) of cardol; and the remainder based on a total of 100 wt % of component (A) being methylcardol and / or anacardic acid. According to an exemplary embodiment, component (A) includes at least 50 wt % of cardanol and at least 35 wt % of cardol with the remainder based on a total of 100 wt % of component (A) being methylcardol and / or anacardic acid.

[0077] Component (A) may be subjected to a heating process (e.g., at the time of extraction from the cashew nut), a decarboxylation process, and / or a distillation process. According to an exemplary embodiment, component (A) is a decarboxylated cashew nutshell liquid that includes at least 50 wt % of cardanol and at least 35 wt % of cardol. Without intending to be bound by this theory, component (A) may increase hydrophobicity, reduce viscosity, increase gel time of the polyurethane resin, and / or provide tensile strength.

[0078] Other potential bio-based components that may be used as a hydroxyl-containing compound in component (A) include soy, zein, castor, grapeseed oil, seaweed oil, jojoba oil. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0079] avocado oil and other plant-based oils. In an embodiment, component (A) includes one or more isolated product from soy, zein, castor, grapeseed oil, seaweed oil, jojoba oil, avocado oil and other plant-based oils. For example, instead of using raw castor oil component (A) may contain ricinoleic acid and / or a triester of glycerol and ricinoleic acid. In addition, it is envisioned that with the present invention one or more of the aforementioned bio-based materials (e.g., soy, zein, castor, grapeseed oil, seaweed oil, jojoba oil, avocado oil and other plant-based oils) or a component isolated therefrom may be derivatized to add a hydroxyl functionality or to increase to increase the hydroxyl count.

[0080] In an embodiment, component (A) has a viscosity ranging from 150 to 450 cps, a viscosity ranging from 200 to 425 cps, a viscosity ranging from 250 to 400 cps, or a viscosity ranging from 300 to 375 cps.

[0081] Further, component (A) can be diluted with water on site at the time of preparation of the coating composition.

[0082] In an embodiment, component (A) comprises sufficient solvent (e.g., water) to suspend the components therein. In an embodiment, the suspension comprising component (A) is substantially homogenous.

[0083] In an embodiment, the amount of solvent in component (A) is at least 10 wt%, at least 10.5 wt%, at least 11 wt%, at least 11.5 wt%, at least 12 wt%, at least 12.5 wt%, at least 13 wt%, at least 13.5 wt%, at least 14 wt%, at least 14.5 wt%, at least 15 wt%, at least 17 wt%, or at least 20 wt°<> of the total composition of component (A). The amount of solvent in component (A) is at most 25 wt%, at most 24 wt%, at most 22 wt%, at most 21 wt%. at most 20 wt%, at most 19.5 wt%, at most 19 wt%, at most 18.5 wt%, at most 18 wt%, at most 17.5 wt%. at most 17 wt%, at most 16.5 wt%, at most 16 wt%. at most 15.5 wt%, or at most 15 wt% of the total composition of component (A). In an embodiment of the invention is any range or sub-range bound by a lower (i. e.. “at least”) and an upper (i.e.. “at most”) limit from Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0084] those selected above. Exemplary ranges include 10 wt% to 25 wt%, 12.5 wt% to 25 wt%, 15 wt% to 25 wt%, 17.5 wt% to 25 wt%, 20 wt% to 25 wt%, 10 wt% to 25 wt%, 10 wt% to 20 wt%, 12.5 wt% to 25 wt%, 12.5 wt% to 20 wt%, 15 wt% to 20 wt%, 10 wt% to 17.5 wt%, 10 wt% to 15 wt%, 12.5 wt% to 17.5 wt%, and 12.5 wt% to 15 wt%.

[0085]

[0086] Component (B) contains an aliphatic isocyanate and / or a cycloaliphatic isocyanate. In an embodiment, component (B) is free from (i.e., has zero) VOCs.

[0087] In an embodiment, component (B) is water-based (i.e., is contained in water as a solvent).

[0088] In an embodiment, component (B) is free from organic solvents.

[0089] The aliphatic isocyanate and / or cycloaliphatic isocyanate may be any compound comprising one or more isocyantate moiety (NCO) which is not directly attached to an aromatic ring.

[0090] In an embodiment, the aliphatic and / or cycloaliphatic isocyanate include 1,6-hexamethylene diisocyanate (HDI; formula (IX)), HDI isocyanurate trimer (formula (X)), 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane (isophorone diisocyanate, IPDI; formula (XI)), and 4,4'-diisocyanato dicyclohexylmethane (H12MDI or hydrogenated MDI; formula (XII)), tetramethylxylylene diisocyanate (TMXDI; formula (XIII)), pentamethylene diisocyanate (PDI; formula (XIV)), or mixtures thereof.

[0091] O N

[0092] N

[0093]

[0094] Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0095] (XIII)

[0096]

[0097] Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0098]

[0099] In an embodiment, component (B) has a viscosity ranging from 400 to 650 cps, a viscosity ranging from 425 to 600 cps, a viscosity ranging from 450 to 550 cps, or a viscosity ranging from 475 to 525 cps.

[0100] Additives

[0101] The component (A) and / or component (B) may include one or more optional additive components.

[0102] In an embodiment, one or more additives can be added after component (A) and component (B) are mixed.

[0103] Exemplary additive components include one or more of a promoter, a defoamer, a deaerating agent, a wetting agent, a flow aid, a drying agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, an anti-mold compound, an anti-mildew compound, an anti-fungus compound, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a UV stabilizer, a corrosion-resistance compound, a rust inhibitor, a filler, reinforcements, a solvent, a chain extender, and / or a crosslinker.

[0104] Where the additive is a nanotube or a microcarrier, the nanotube and / or microcarrier may contain additives including at least one of titanium dioxide, a pigment, and an antimicrobial agent.

[0105] Exemplary cataly sts include catalysts include tertiary amines, Mannich bases formed from secondary amines, nitrogen-containing bases, alkali metal hydroxides, alkali phenolates, alkali metal alcoholates, hexahydrothiazines, and organometallic compounds. An exemplary Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0106] catalyst is a zirconium chelate complex, dibutyltin dilaurate, an organotin compound. The catalyst may be added, in amount from 0.001 wt % to 10 wt %, based on the total weight of the system. The catalyst may accelerate the curing time of isocyanate moieties (e.g., in the isocyanate component or in prepolymers) and active hydrogens (e.g., polyols and / or chain extenders) to offer mechanical properties.

[0107] An exemplary antimicrobial agent is a 2: 1 blend of emulsified water-based silver solution and zinc-pyrithione.

[0108] Dyes and / or pigments (such as titanium dioxide and / or carbon black), may be included in the additive component to impart color properties to the polyurethane coatings. Pigments may be in the form of solids or a dispersion in a resin carrier.

[0109] Reinforcements (e.g., flake or milled glass and / or fumed silica), may be used to impart certain properties.

[0110] Curing agents include amines (e.g., ethylene diamine, diethyl enetriamine and lentine), hexamethylene tetramine (e.g., urotropine), acid-anhydrides (e.g., phthalic anhydride and maleic anhydride) and macromolecules (e.g., polyamide resin).

[0111] Drying agents include calcium chloride, potassium carbonate, sodium sulfate, calcium sulfate, magnesium sulfate, magnesium perchlorate, aluminum oxide, silica gel, molecular sieves, sulfuric acid, phosphorous pentoxide.

[0112] In an embodiment, tin compounds may be included as the coating composition either in component (A), component (B), or added to the mixture of component (A) and component (B). Examples of tin compounds include stannous octoate, stannous neodecanoate, dibutyltin dilaurate, dibutyltin oxide, a methyltin compound, and an ocyltin compound.

[0113] The coating system may be a curable composition that includes curing agent / hardener component in addition to the coating system or as part of the coating system. The amount of the hardener component used may vary depending on whether the hardener component is Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0114] used in addition to or as part of the coating system. In exemplary embodiments, an amine-based hardener (e.g., one that is known in the art for use in curing epoxy systems) may be excluded because the sprayable polyurethane systems rely on urethane curing chemistry due to minimal residual epoxy content.

[0115] Other additives include, e.g., UV light stabilizers, antioxidants, air release agents, and adhesion promoters, which may be independently used depending on the desired characteristics of the polyurethane coating.

[0116] The additives addition amount will vary depending upon the end use. In an embodiment, the total amount of all additives (based on the total of the coating composition including components (A) and (B)) is no more than 25 wt% no more than 20 wt%, no more than 15 wt%, not more than 10 wt%, or no more than 5 wt%. As an example, where the additive is a defoamer, the total amount is 2 to 9 wt%, 3 to 8 wt%, or 4 to 7 wt%.

[0117] Alternatively, where the coting composition contains a UV light stabilizer, the amount ranges from 1 to 4 wt% or 2 to 3 wt%.

[0118] Other exemplary additives and amounts include:

[0119] A reactive surfactant, for example 3-n-pentadecylphenol, with an equivalent weight of from 250 to 300, at an amount of from 1 to 5 wt% or 2 to 4 wt%.

[0120] A diamine with an equivalent weight ranging from 130 to 160, and an amount of from 3 to 9 wt% or 5 to 7 wt%.

[0121] An antimicrobial agent, for example, silver solution and zinc pyrithione, at an amount of from 0.5 to 1.5 wt% or 0.75% to 1.25%.

[0122] A comprehensive review of coatings additives is given in " Lehrbuch der Lacke und Beschichtungen [Textbook on paints and coatings], volume III. " Losemittel. Weichmacher, Additive. Zwischenprodukte” [Solvents, plasticizers, additives, intermediates]. H. Kittel. Verlag W. A. Colomb in derHeenemann GmbH, Berlin-Oberschwandorf, 1976, pp. 237-398. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0123] Kits

[0124] The present invention includes an embodiment where a kit is provided such that component (A) and component (B) are contained in discrete and separate containers together with instructions for preparing and / or using the coating composition.

[0125] In the kits of the present invention, the additives may be present in component (A) and / or component (B). Alternatively, the additives may be contained in their own separate container(s) for addition as applicable to the desired use. For example, dyes and / or pigments may be stored in a separate container in the kit such that they can be added in the desired amount to achieve the tint desired.

[0126] Storage temperatures for the kit (and independently for components (A) and / or component (B)) should be 45° to 90°F, 55° to 85°F, or 60° to 80°F. Freezing temperatures, direct sunlight, & moisture should be avoided. Further, the kit (and independently for components (A) and / or component (B)) should not be exposed to direct heat and / or should be kept away from heat sources.

[0127] Coating Method and Coating Composition

[0128] The coating composition of the present invention may be applied to a surface of a material after mixing components (A) and (B).

[0129] In an embodiment, the coating composition is first prepared for application by:

[0130] (1) Stirring, shaking, or agitating component (A) for a time and under conditions to fully disperse the hydroxyl-containing compound and component;

[0131] (2) Adding component (B), which has been optionally stirred, shaken, or agitated for a time and under conditions to fully disperse the aliphatic isocyanate and / or cycloaliphatic isocyanate; and Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0132] (3) Mixing components (A) and (B) for a time sufficient to substantially blend components (A) and (B).

[0133] The component (A) and / or component (B) may include one or more additive components.

[0134] The time and conditions for stirring, shaking, or agitating in (1) and / or (2) is not particularly limited so long as it is sufficient to ensure that component (A) and component (B), respectively, are fully dispersed in the solvent. The time and conditions would be understood to the skilled artisan. Exemplary times are from 15 seconds to 5 minutes, from 30 seconds to 4 minutes, from 1 minute to 3 minutes. Stirring can be accomplished by using a jiffy blade mixer at a slow speed (e.g., 400 rpm, 450 rpm, 500 rpm, 550 rpm, 600 rpm).

[0135] Mixing in (3) is for a time sufficient to substantially blend components (A) and (B). “Substantially blend” in this context means that components (A) and (B) are mixed well and in a manner that permits creation of an approximately uniform dispersion. In an embodiment, the mixing time is from 30 seconds to 5 minutes, from 1 minute to 4 minutes, from 2 minutes to 3 minutes.

[0136] In an embodiment, one or more additives can be added after component (A) and component (B) are mixed in (3).

[0137] In an embodiment, the mixing ratio of components (A) and (B) (i.e, a weight ratio of (A): (B)) is at least 0.5:1, at least 0.6:1, at least 0.7:1, at least 0.8:1, at least 0.9:1, at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.3: 1, at least 1.4: 1, at least 1.5:1, at least 1.6:1, at least 1.7: 1, at least 1.8: 1, at least 1.9: 1, or at least 2:1. The mixing ratio of components (A) and (B) (i.e, a weight ratio of (A): (B)) is at most 3:1, at most 2.9: 1, at most 2.8:1, at most 2.7:1, at most 2.6:1, at most 2.5:1, at most 2.4:1. at most 2.3:1, at most 2.2:1, at most 2.1:1. at most 2:1, at most 1.9:1, at most 1.8:1. at most 1.7:1, at most 1.6:1, or at most 1.5:1. In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0138] an upper (i.e., “at most”) limit from those selected above. Exemplary ranges include from 0.5:1 to 3:1, from 0.5:1 to 2.5:1, from 0.5:1 to 2:1, from 0.5:1 to 1.5:1, from 1:1 to 3:1, from 1:1 to 2.5:1, from 1:1 to 2:1, from 1:1 to 1.5:1, from 1.5:1 to 3:1, from 1.5:1 to 2.5:1, from 1.5:1 to 2:1, from 1.2:1 to 2.8:1, from 1.4:1 to 2.6:1, from 1.5:1 to 2.5:1, from 1.6:1 to 2.4:1, from 1.8:1 to 2.2:1, from 1.2:1 to 1.8:1, or from 1.2:1 to 1.6:1.

[0139] In the preparation method above, the coating composition may optionally be allowed stand for a time ranging from 30 seconds to 5 minutes, from 1 minute to 4 minutes, from 2 minutes to 3 minutes prior to being applied to a surface of a material. This standing time initiates the reaction between the hydroxyl-containing compound in component (A) and the aliphatic isocyanate and / or a cycloaliphatic isocyanate in component (B), which may help with curing of the coating on the surface of the material.

[0140] The coating composition of the present invention prepared by the foregoing method has a pot life of from 1 to 5 hours, from 1.5 to 4 hours, or from 2 to 3 hours at 75°F and 50% RH.

[0141] In an embodiment, the coating composition is VOC-free.

[0142] In an embodiment, the coating composition has no odor after mixing.

[0143] In an embodiment, the coating composition has a pH after mixing ranging from 6.5 to 7.5, from 6.7 to 7.3, from 6.9 to 7.1.

[0144] In an embodiment, the coating composition has a viscosity after mixing ranging from 400 to 650 cps, from 425 to 600 cps, from 450 to 550 cps, or from 475 to 525 cps.

[0145] The coating composition contains a total of at least 15 wt%, at least 20 wt%, at least 24 wt%, at least 25 wt%. at least 27.5 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%. at least 55 wt%, or at least 60 wt% of bio-based materials (e.g.. a plant-based and / or bio-renewable polymer). The coating composition contains a total of at most 95wt%, at most 90 wt%, at most 85 wt%, at most 80 wt%, at most 75 wt%, at most Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0146] 70 wt%, at most 65 wt%, at most 60 wt%, at most 55 wt%, at most 50 wt%, at most 45 wt%. at most 40 wt%, or at most 35 wt% of bio-based materials (e g., a plant-based and / or biorenewable materials). In an embodiment of the invention is any range or sub-range bound by a lower (i.e., “at least”) and an upper (i.e., “at most”) limit from those selected above.

[0147] Exemplary ranges include: 15 wt% to 95 wt%, 20 wt% to 95 wt%, 24 wt% to 95 wt%, 30 wt% to 95 wt%, 35 wt% to 95 wt%, 40 wt% to 95 wt%, 15 wt% to 85 wt%, 20 wt% to 85 wt%, 24 wt% to 85 wt%, 30 wt% to 85 wt%, 35 wt% to 85 wt%, 40 wt% to 85 wt%, 15 wt% to 75 wt%, 20 wt% to 75 wt%, 24 wt% to 75 wt%, 30 wt% to 75 wt%, 35 wt% to 75 wt%, 40 wt% to 75 wt%, 15 wt% to 65 wt%, 20 wt% to 65 wt%, 24 wt% to 65 wt%, 30 wt% to 65 wt%, 35 wt% to 65 wt%, 40 wt% to 65 wt%, 15 wt% to 50 wt%, 20 wt% to 50 wt%, 24 wt% to 50 wt%, 30 wt% to 50 wt%, 35 wt% to 50 wt%, and 40 wt% to 50 wt%.

[0148] In an embodiment, after mixing, the coating composition containing component (A) and component (B) has a high solids content of over 60%, over 70%, over 75%, over 80%, over 85%, or over 90%, for example from 60 to 95%, from 70 to 95%, from 75 to 90% or from 80 to 90%. This very high solids content reduces transportation costs.

[0149] Depending upon the surface to be treated, the application method, and the desired coating thickness, among other factors, the coating composition of the present invention may be diluted by up to 50% (i.e., add an equal amount of solvent to the volume of the mixed coating composition), up to 40%, up to 30%, up to 25%, up to 20%, up to 15%, or up to 10% with a solvent after components (A) and (B) are mixed. Thinning is also desirable for some applications to avoid lap marks and / or to allow for proper self-leveling characteristics. The solvent is preferably water.

[0150] After components (A) and (B) are mixed together there is less than 10 wt%, less than 7.5 wt%. less than 5 wt%, less than 2.5 wt%, or no free aliphatic isocyanate (and / or cycloaliphatic isocyanate) in the coating composition. Not to be bound to any specific theory Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0151] or mechanism, but any free isocyanate is expected to immediately convert to aliphatic (and / or cycloaliphatic) polyurethane which is also water-based.

[0152] Application thickness should be 1 to 6 mils, 2 to 5 mils, or 3 to 4 mils with each application thereof to achieve a total thickness of from 0.001 to 0.500 inches (1 - 500 mils), from 0.002 to 0.250 inches (2 - 250 mils), from 0.003 to 0.200 inches (3 - 200 mils), from 0.004 to 0.100 inches (4 to 100 mils), or from 0.005 to 0.050 inches (5 to 50 mils). Of course, thinner coatings are also envisioned of from 1 to 50 mils, 2 to 25 mils, 3 to 20 mils, 4 to 15 mils, or 5 to 10 mils.

[0153] The coating composition may be applied to the surface of a material by brushing, rolling, or spraying. The coating composition of the present invention has a coverage rate of approximately 250 to 400 sq. ft. per gallon; however, the coverage rate is impacted by the material (e.g., substrate) to be treated, the surface pretreatment, and whether or not the coating composition was diluted before application. The following table includes approximate coverage rates for different substrates:

[0154] Substrate Sq Ft / Gallon Textured Surface ~ 250-300

[0155] All Masonry Surface - 300

[0156] Painted Surfaces - 400

[0157] Wood Surfaces - 300

[0158] Metal - 400

[0159] Tile - 350

[0160]

[0161] Following application to the surface of a material, the coating composition of the present invention has a dry-time ranging from 2 to 15 hours, from 3 to 14 hours, from 4 to 13 Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0162] hours, from 5 to 12 hours, from 6 to 11 hours, or from 7 to 10 hours, but the drying time varies depending upon the temperature, ventilation, and catalyst system being used. For example, the drying time at ambient temperature may be 8 hours or less.

[0163] After preparing the coating composition, a process for curing the composition may be used to form a thermoset or cured composition. For example, the composition or formulation may be cured under conventional processing conditions to form a film, a coating, or a solid. Curing the coating composition may be carried out at curing reaction conditions including a predetermined temperature and for a predetermined period of time sufficient to cure the composition. The curing conditions may be dependent on the various components used in the curable composition such as the hardener used in the formulation. The curing reaction conditions include, e.g., carrying out the reaction under a temperature, generally in the range of from -5° C. to 60° C. (e.g., 0° C. to 50° C., 5° C. to 25° C., etc.). For sprayable applications, the coating may be applied to substrates, e.g., using airless sprayers and air-assisted pneumatic sprayers and the like. The applied composition may be cured by heating the composition at the aforementioned curing temperatures.

[0164] Following drying of a first layer or when the coating is tack free, a second coating layer may be applied by spraying, rolling, or brushing. However, for proper adhesion, it is desired to apply the second coat within 24 hours, within 18 hours, within 12 hours, or within 6 hours of application of the first coat. If the first coat has dried longer than 24-hours, the surface may be abraded or etched to promote adhesion of the second coat.

[0165] Temperature and humidity directly affect pot life and dry time. Accordingly, in an embodiment the conditions should be between 40 - 95 °F, between 50 and 85 °F, between 60 and 80 °F, or between 65 and 75 °F and the humidity should not exceed 80%, not exceed 70%. not exceed 60%, or not exceed 50%. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0166] In an embodiment, the surface to be coated has a moisture content of no more than 25%, no more than 20%, no more than 15%, no more than 10%, or no more than 5% as measured with an electronic moisture meter.

[0167] Prior to application of the coating composition to a surface, the surface may pretreated and / or cleaned.

[0168] In an embodiment, the surface to be coating may be cleaned prior to application of the coating composition. For example, to facilitate proper penetration and sealing of the coating, the surface can be cleaned to remove dirt, debris, grime, minerals such as lime and calcium, oils, release agents, grease, mud, excess mortar, and mold and mildew, etc.

[0169] In an embodiment, the surface may be pretreated with a primer (e.g., smooth surfaces) or a sealer or filler to remove pinholes (e.g., porous surfaces). Another envisioned pretreatment includes pointing and / or caulking all cracks. Further, all voids, beeholes, masonry surface defects and openings such as conduits, pipes, drains, door frames, vents, air conditioner openings, electrical openings, control joints, or any dissimilar materials should be repaired using urethane or other approved patching.

[0170] Another form of surface pretreatment envisioned in the present invention includes fluting, scoring, sandblasting, and / or etching as well as raking joints. Pretreating a surface in this manner can increase the absorption, but will also lower coverage rates.

[0171] In an embodiment, the coating composition is not applied where freezing temperatures have existed prior to application. In such a situation, adequate time should be allowed for the application surface to thaw. In an embodiment, air, surface, and material temperatures should be above 40°F (4.4°C) and at least 5°F above the dew point prior to application. Further, it is not desirable to apply the coating composition where temperatures are below 40°F or when temperatures are expected to drop below 40°F within 48 hours of application. For exterior surfaces, application should also be avoided if rain, snow, or lower Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0172] temperatures are expected within 48 hours. Further, the coating composition would be adversely affective if relative humidity is greater than 90% and, therefore, it should be avoided.

[0173] In the case of spills or following application excess coating composition can be cleaned up with water.

[0174] Coated Products

[0175] The coating composition of the present invention finds utility in many different industries including oil and gas, steel fabrication, bridge and highway, power generation, pharmaceutical, marine, food processing, veterinary, hospitals, and restaurants.

[0176] An exemplary use includes floors of food processing, veterinary, hospitals, restaurants and other facilities that need to have a floor coating with high gloss, mold resistance, and mildew resistance. Other uses include warehouses, food and beverage facilities, USDA inspected facilities, commercial vehicles, airports, stadiums, sound walls, stadiums, direct-to-metal, aluminum & metal, galvanized & ungalvanized steel.

[0177] The coating composition is suitable for and has excellent adherence to properties to a broad scope of materials including asphalt, ceramic, glass, concrete, wood, metal (including aluminum), galvanized steel, ungalvanized steel, tile, paper packaging, a composite, plastic, and textiles.

[0178] Thus, within the scope of the present invention are materials having a coating made from the coating composition of the present invention. In an embodiment, the coating on the materials is at a total thickness of from 0.001 to 0.500 inches (1 - 500 mils), from 0.002 to 0.250 inches (2 - 250 mils), from 0.003 to 0.200 inches (3 - 200 mils), from 0.004 to 0.100 inches (4 to 100 mils), or from 0.005 to 0.050 inches (5 to 50 mils). Of course, thinner Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0179] coatings are also envisioned of from 1 to 50 mils, 2 to 25 mils, 3 to 20 mils, 4 to 15 mils, or 5 to 10 mils.

[0180] The coating composition MEK double rub @ 50% solids: passed 6,000-8,000 cycles pursuant to ASTM D7835, EN 13523-11, Reference: ASTM D4752, ASTM D2486, ASTM D5402; ISO 50230).

[0181] Benefits

[0182]

[0183] Contains at least 28 wt% of plant-based bio-renewable polymer.

[0184] The gloss is excellent (MEK double rub @ 50% solids: passed 6,000-8,000 cycles). Exhibits excellent adhesion on most surfaces.

[0185] Chemical and acid resistance is excellent.

[0186] • Examples include: ammonium hydroxide, potassium hydroxide, sodium hydroxide, sodium chloride, trisodium phosphate, ethyl alcohol, isopropyl alcohol, Hyjet #3, Skydrol 500 A & B, hydrochloric acid 10%, phosphoric acid 35%, toluene, xylene, jet fuel - butyl cellosolve, acetone - cellosolve acetate, methyl ethyl ketone, sulfuric acid 20%, acetic acid 24%, trichlorethylene, methyl alcohol, perchlorethylene, beer, cola, milk, mustard, and bleach

[0187] Can be applied both exterior and interior exposed surfaces.

[0188] - Has excellent resistance to mold, mildew, and fungus.

[0189] - Has good corrosion resistance.

[0190] Scratch resistant.

[0191] - Non-yellowing & UV resistant topcoat.

[0192] - Anti-carbonation protection.

[0193] Can be applied directly to metal and concrete. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0194] Excellent as a protective floor coating, or topcoat applied over a primer epoxy, as a high-gloss, chemical / acid resistant topcoat for industrial concrete flooring applications.

[0195] Breathable elastomeric waterproofer.

[0196] The present invention is exemplified by the following embodiments:

[0197] [1] A two-component coating system comprising:

[0198] component (A) comprises a hydroxyl-containing compound and

[0199] component (B) comprises an aliphatic isocyanate and / or a cycloaliphatic isocyanate wherein the coating system is water-based and free from volatile organic compounds.

[0200] [2] The coating system of [1], wherein component (A) comprises a CNSL-derived polyol and / or a cardanol compound.

[0201] [3] The coating system of [1] or [2], wherein component (A) comprises cardanol compounds comprising from 35 to 55 wt% of tri -unsaturated cardanol, from 25 to 40 wt% mono-unsaturated cardanol, from 15 to 30 wt% bi-unsaturated cardanol, and 1 to 5% saturated cardanol.

[0202] [4] The coating system of any one of [1] - [3], wherein component (A) further comprises cardol, methylcardol, and / or anacardic acid.

[0203] [5] The coating system of any one of [1] - [4], wherein component (A) comprises at least 50 wt% cardanol and at least 35 wt % of cardol with the remainder based on a total of 100 wt % of component (A) being methylcardol and / or anacardic acid of the total cardanol compounds.

[0204] [6] The coating system of any one of [1] - [5]. wherein component (A) has a viscosity ranging from 150 to 450 cps. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0205] [7] The coating system of any one of [1] - [6], wherein component (B) is selected from the group consisting of 1,6-hexamethylene diisocyanate (HDI), HDI isocyanurate trimer, l-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane, 4,4'-diisocyanato dicyclohexylmethane, tetramethylxylylene diisocyanate, and pentamethylene diisocyanate.

[0206] [8] The coating system of any one of [1] - [7], wherein component (B) has a viscosity ranging from 400 to 650 cps.

[0207] [9] The coating system of any one of [1] - [8], wherein component (A), component (B), both, or a mixture of component (A) and component (B) further comprises an additive and said additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a flow aid, a drying agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, an anti-mold compound, an anti-mildew compound, an anti-fungus compound, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a UV stabilizer, a corrosion-resistance compound, a rust inhibitor, a filler, reinforcements, a solvent, a chain extender, and a crosslinker.

[0208]

[0010] A kit comprising, separately packaged component (A) and component (B) together with instructions for use thereof, wherein

[0209] component (A) comprises a hydroxyl-containing compound and

[0210] component (B) comprises an aliphatic isocyanate and / or a cycloaliphatic isocyanate wherein component (A) and component (B) are water-based and free from volatile organic compounds.

[0211]

[0011] The kit of

[0010] , further comprising one or more separately packaged additives selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a flow aid, a drying agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, dyes, a pigment, an antimicrobial agent, an Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0212] anti-mold compound, an anti-mildew compound, an anti-fungus compound, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a UV stabilizer, a corrosion-resistance compound, a rust inhibitor, a filler, reinforcements, a solvent, a chain extender, and a crosslinker.

[0213]

[0012] A method of making a coating composition, comprising

[0214] (1) Stirring, shaking, or agitating a component (A) comprising a hydroxyl-containing compound for a time and under conditions to fully disperse the hydroxyl-containing compound and component;

[0215] (2) Adding a component (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate, which has been optionally stirred, shaken, or agitated for a time and under conditions to fully disperse the aliphatic isocyanate and / or cycloaliphatic isocyanate; and

[0216] (3) Mixing components (A) and (B) for a time sufficient to substantially blend components (A) and (B) to form a coating composition.

[0217]

[0013] The method of

[0012] , wherein the mixing ratio of component (A):component (B) is from 0.5:1 to 3:1.

[0218]

[0014] The method of

[0012] or

[0013] , further comprising holding the coating composition for a time ranging from 30 seconds to 5 minutes before further use.

[0219]

[0015] The method of any one of

[0012] -

[0014] , wherein after mixing the coating composition has a solids content of 60 to 95%.

[0220]

[0016] A method of coating a surface of a material with a coating composition, comprising: applying a coating composition prepared by the method of any one of

[0013] -

[0015] to the surface of the material and allowing the coating composition to cure.

[0221]

[0017] The method of

[0016] . wherein the total coating thickness ranges from 1 to 50 mils. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0222]

[0018] The method of

[0016] or

[0017] , wherein the material is selected from the group consisting of ceramic, glass, concrete, wood, aluminum, metal, galvanized steel, ungalvanized steel, tile, and textiles.

[0223]

[0019] A coated material, wherein said material has a coating thereon wherein the coating comprises the reaction product of a component (A) comprising ahydroxyl-containing compound and a component (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate, wherein the coating contains no VOCs and has at least 15 wt% of a bio-based material.

[0224]

[0020] The coated material of

[0019] , wherein component (A) comprises a CNSL-derived polyol and / or a cardanol compound.

[0225]

[0021] The coated material of

[0019] or

[0020] , wherein component (A) comprises cardanol compounds comprising from 35 to 55 wt% of tri-unsaturated cardanol, from 25 to 40 wt% mono-unsaturated cardanol, from 15 to 30 wt% bi-unsaturated cardanol, and 1 to 5% saturated cardanol.

[0226]

[0022] The coated material of any one of

[0019] -

[0021] , wherein component (A) further comprises cardol, methylcardol, and / or anacardic acid.

[0227]

[0023] The coated material of any one of

[0019] -

[0022] , wherein component (A) comprises at least 50 wt% cardanol and at least 35 wt % of cardol with the remainder based on a total of 100 wt % of component (A) being methylcardol and / or anacardic acid of the total cardanol compounds.

[0228]

[0024] The coated material of any one of

[0019] -

[0023] , wherein component (B) is selected from the group consisting of 1,6-hexamethylene diisocyanate (HDI), HDI isocyanurate trimer, l-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane, 4,4'-diisocyanato dicyclohexylmethane, tetramethylxylylene diisocyanate, and pentamethylene diisocyanate. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0229]

[0025] The coated material of any one of

[0019] -

[0024] , wherein the coating further comprises an additive and said additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a flow aid, a drying agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, an anti-mold compound, an anti-mildew compound, an anti-fungus compound, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a UV stabilizer, a corrosion-resistance compound, a rust inhibitor, a filler, reinforcements, a solvent, a chain extender, and a crosslinker.

[0230]

[0026] The coated material of any one of

[0019] -

[0025] , wherein the material is selected from the group consisting of asphalt, ceramic, glass, concrete, wood, aluminum, metal, galvanized steel, ungalvanized steel, tile, paper packaging, a composite, plastic, and textiles.

[0231] In the context of the present description, all publications, patent applications, patents and other references mentioned herein, if not otherwise indicated, are explicitly incorporated by reference herein in their entirety for all purposes as if fully set forth, and shall be considered part of the present disclosure in their entirety.

[0232] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In case of conflict, the present specification, including definitions, will control.

[0233] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0234] the marketplace, or to enable others or ordinary skill in the art to understand the embodiments disclosed herein.

[0235] Except where expressly noted, trademarks are shown in upper case.

[0236] Unless stated otherwise, all percentages, parts, ratios, etc., are by weight.

[0237] When an amount, concentration, or other value or parameter is given as a range, or a list of upper and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper and lower range limits, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the present disclosure be limited to the specific values recited when defining a range. Further, where a numerical limit or range is stated herein, the endpoints are included. Also, all values and subranges within a numerical limit or range are specifically included as if explicitly written out.

[0238] Further, unless otherwise explicitly stated to the contrary, when one or multiple ranges or lists of items are provided, this is to be understood as explicitly disclosing any single stated value or item in such range or list, and any combination thereof with any other individual value or item in the same or any other list.

[0239] When the term "about" is used, it is used to mean a certain effect or result can be obtained within a certain tolerance, and the skilled person knows how to obtain the tolerance. When the term "about" is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to.

[0240] As used herein, the terms "comprises," "comprising." "includes," "including," "has." "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0241] necessarily limited to only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0242] The transitional phrase "consisting of excludes any element, step, or ingredient not specified in the claim, closing the claim to the inclusion of materials other than those recited except for impurities ordinarily associated therewith. When the phrase "consists of appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0243] The transitional phrase "consisting essentially of limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. A “consisting essentially of’ claim occupies a middle ground between closed claims that are written in a “consisting of’ format and fully open claims that are drafted in a “comprising” format. Optional additives as defined herein, at a level that is appropriate for such additives, and minor impurities are not excluded from a composition by the term “consisting essentially of’.

[0244] As used herein, an "embodiment" means that a particular feature, structure or characteristic is included in at least one or more manifestations, examples, or implementations of this invention. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art. Combinations of features of different embodiments are all meant to be within the scope of the invention, without the need for explicitly describing every possible permutation by example. Thus, any of the claimed embodiments can be used in any combination.

[0245] Further, unless expressly stated to the contrary, “and / or” refers to an inclusive and not to an exclusive. Thus, “and / or” should be understood to mean “either or both” of the Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0246] elements so conjoined, e g., elements that are conjunctively present in some cases and disjunctively present in other cases. For example, a condition A and / or B, is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0247] The use of "a" or "an" to describe the various elements and components herein is merely for convenience and to give a general sense of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. Similarly, the adjective ‘‘another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements.

[0248] The above written description of the invention provides a manner and process of making and using it such that any person skilled in this art is enabled to make and use the same, this enablement being provided in particular for the subject matter of the appended claims, which make up a part of the original description.

[0249] As used herein, the phrases “selected from the group consisting of,” “chosen from,” and the like include mixtures of the specified materials.

[0250] The above written description of the invention provides a manner and process of making and using it such that any person skilled in this art is enabled to make and use the same, this enablement being provided in particular for the subject matter of the appended claims, which make up a part of the original description.

[0251] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)

[0252] The above description is presented to enable a person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, this invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.

[0253] Having generally described this invention, a further understanding can be obtained by reference to certain specific examples, which are provided herein for purposes of illustration only, and are not intended to be limiting unless otherwise specified.

[0254] EXAMPLE

[0255] A coating composition of the present invention was prepared at 30% bio-based total content and coated (100%, 30 pulls) on tile and wood (see Fig. 1) and aluminum (see Fig. 2). Fig. 2 shows the results of the MEK double rub test at 5000, 6000, and 8000 double rubs. As shown in Fig. 2 the coating composition of the present invention last 4-6 times longer than conventional coating compositions, which typically survive less than 2000 double rubs.

[0256] Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.

Claims

Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)CLAIMSWhat we claim is1. A two-component coating system comprising:component (A) comprising 35 wt% to 100 wt% of a hydroxyl-containing compound andcomponent (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate, wherein the mixing ratio of component (A): component (B) is from 0.5:1 to 3:1, wherein the system comprises 15 wt% to 95 wt% of bio-based materials, and wherein the coating system is water-based and free from volatile organic compounds.

2. The coating system of claim 1, wherein component (A) comprises a CNSL-derived polyol and / or a cardanol compound.

3. The coating system of claim 1, wherein component (A) comprises cardanol compounds comprising from 35 to 55 wt% of tri -unsaturated cardanol, from 25 to 40 wt% mono-unsaturated cardanol, from 15 to 30 wt% bi-unsaturated cardanol, and 1 to 5% saturated cardanol.

4. The coating system of claim 4, wherein component (A) comprises at least 50 wt% cardanol and at least 35 wt % of cardol with the remainder based on a total of 100 wt % of component (A) being methylcardol and / or anacardic acid of the total cardanol compounds.

5. The coating system of claim 1, wherein component (B) is selected from the group consisting of 1,6-hexamethylene diisocyanate (HDI), HDI isocyanurate trimer, 1-isocyanato-Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane, 4,4'-diisocyanato dicyclohexylmethane, tetramethylxylylene diisocyanate, and pentamethylene diisocyanate.

6. The coating system of claim 1, wherein component (A), component (B), both, or a mixture of component (A) and component (B) further comprises an additive and said additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a flow aid, a drying agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology' modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, an anti-mold compound, an anti-mildew compound, an anti-fungus compound, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a UV stabilizer, a corrosion-resistance compound, a rust inhibitor, a filler, reinforcements, a solvent, a chain extender, and a crosslinker.

7. A kit comprising, separately packaged component (A) and component (B) together with instructions for use thereof, whereincomponent (A) comprises 35 wt% to 100 wt% of a hydroxyl-containing compound andcomponent (B) comprises an aliphatic isocyanate and / or a cycloaliphatic isocyanate wherein component (A) and component (B) are water-based and free from volatile organic compounds.

8. The kit of claim 7, further comprising one or more separately packaged additives selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a flow aid, a drying agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, dyes, a pigment, an antimicrobial agent, anAttorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)anti-mold compound, an anti-mildew compound, an anti-fungus compound, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a UV stabilizer, a corrosion-resistance compound, a rust inhibitor, a filler, reinforcements, a solvent, a chain extender, and a crosslinker.

9. A method of making a coating composition, comprising(1) Stirring, shaking, or agitating a component (A) comprising 35 wt% to 100 wt% of a hydroxyl-containing compound for a time and under conditions to fully disperse the hydroxyl-containing compound;(2) Adding a component (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate, which has been optionally stirred, shaken, or agitated for a time and under conditions to fully disperse the aliphatic isocyanate and / or cycloaliphatic isocyanate, wherein the mixing ratio of component (A):component (B) is from 0.5:1 to 3:1; and(3) Mixing components (A) and (B) for a time sufficient to substantially blend components (A) and (B) to form a coating composition, wherein the composition comprises 15 wt% to 95 wt% of bio-based materials.

10. The method of claim 9, wherein after mixing the coating composition has a solids content of 60 to 95%.

11. A method of coating a surface of a material with a coating composition, comprising: applying a coating composition prepared by the method of claim 9 to the surface of the material and allowing the coating composition to cure.Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)12. The method of claim 11, wherein the total coating thickness ranges from 1 to 50 mils.

13. The method of claim 11, wherein the material is selected from the group consisting of ceramic, glass, concrete, wood, aluminum, metal, galvanized steel, ungalvanized steel, tile, and textiles.

14. A coated material, wherein said material has a coating thereon wherein the coating comprises the reaction product of a component (A) comprising 35 wt% to 100 wt% of a hydroxyl-containing compound and a component (B) comprising an aliphatic isocyanate and / or a cycloaliphatic isocyanate, wherein the mixing ratio of component (A):component (B) is from 0.5: 1 to 3: 1, wherein the coating contains no VOCs, and the coating has at least 15 wt% of a bio-based material.

15. The coated material of claim 14, wherein component (A) comprises a CNSL-derived polyol and / or a cardanol compound.

16. The coated material of claim 14, wherein component (A) comprises cardanol compounds comprising from 35 to 55 wt% of tri-unsaturated cardanol, from 25 to 40 wt% mono-unsaturated cardanol, from 15 to 30 wt% bi-unsaturated cardanol, and 1 to 5% saturated cardanol.

17. The coated material of claim 14. wherein component (A) comprises at least 50 wt% cardanol and at least 35 wt % of cardol with the remainder based on a total of 100 wt % of component (A) being methylcardol and / or anacardic acid of the total cardanol compounds.Attorney Docket No.: 40787 / 67 (BIOB-Ol / OIWO)18. The coated material of claim 14, wherein component (B) is selected from the group consisting of 1,6-hexamethylene diisocyanate (HDI), HDI isocyanurate trimer, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane, 4,4'-diisocyanato dicyclohexylmethane, tetramethylxylylene diisocyanate, and pentamethylene diisocyanate.

19. The coated material of claim 14, wherein the coating further comprises an additive and said additive is one or more selected from the group consisting of a promoter, a defoamer, a deaerating agent, a wetting agent, a flow aid, a drying agent, a dispersant, a levelling agent, a dispersed paraffin wax, a thickener, a rheology modifier, an emulsifier, a dye, a pigment, an antimicrobial agent, an anti-mold compound, an anti-mildew compound, an anti-fungus compound, a nanotube, a microcarrier, a curative agent, a catalyst, a surfactant, a plasticizer, a UV stabilizer, a corrosion-resistance compound, a rust inhibitor, a filler, reinforcements, a solvent, a chain extender, and a crosslinker.

20. The coated material of claim 14, wherein the material is selected from the group consisting of asphalt, ceramic, glass, concrete, wood, aluminum, metal, galvanized steel, ungalvanized steel, tile, paper packaging, a composite, plastic, and textiles.

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