Thermally insulating coating compositions

Abstract

The present invention relates to air-drying, thermally insulating coating composition for applying to a substrate, the coating composition comprising at least from 15% to 80% by weight of a film forming binder, from 10% to 70% by weight of an inorganic porous and inorganic non-porous hydrophobic particles having a D50 particle size range of between 30 µm and 300 µm and a D95 inorganic particle size range of between 2.0 µm and 1000 µm, where the dry weight percentage of the inorganic particles is based upon a dry weight ratio of specific particle size ranges, being a "large" particle size range of between 300 µm to 1000 µm, a "medium" particle size range of between 100 µm to 300 µm, and a "small" particle size range of between 10 µm to 100 µm; and wherein the ratio of "large" to "medium" to "small" particle size ranges is in a ratio of between 3:2:1 and 3:2:2, whereby after applying the coating composition to a substrate, the coating composition forms a coating film and provides an insulation barrier to the transfer of heat from one side of the coating film to the other side of the coating film. The coatings derived from the compositions of the invention may be applied by spray, roller or trowel and may be applied to any substrate surface such as wood, metal, masonry, plastics or composites.

Description

[0001] THERMALLY INSULATING COATING COMPOSITIONS

[0002] Field of Invention

[0003] The present invention relates to thermally insulating coating compositions and in particular, to coating compositions that can be applied to any surface substrate such as wood, metal, masonry or plastics.

[0004] Background of Invention.

[0005] Heat transfer between materials occurs through one or more processes, these being conduction, convection, and radiation. Heat moves through a solid by conduction and the rate of conduction depends on both the chemical nature and structure of the solid. Convection is the transfer of heat by the movement of a fluid, such as a liquid or gas. Radiation is the transfer of heat between materials through electromagnetic waves.

[0006] The thermal conductivity (K) of a material is the rate at which heat flows through a material between two points at different temperatures. It is measured in units of Watt’s per meter per degree Kelvin (W / mK). The heat flux (Q) is the rate at which energy is transferred through a given surface and is most often measured by using a temperature difference over a piece of material with a known thermal conductivity. For a material to exhibit a thermal insulative property, it must have a very low thermal conductivity.

[0007] The inadvertent transfer of thermal energy in the form of heat leads to a variety of problems in both commercial and industrial settings. Such problems include heat loss from processing equipment and piping, increased energy usage, worker injuries from contact with hot surfaces with the associated human and financial costs.

[0008] The traditional insulation methods for both flat and curved surfaces used a variety of rigid and flexible insulation media. Rigid insulation media include polyisocyanurate (PIR) foam, expanded polystyrene foam, phenolic foam. Commonly used flexible insulation media include rockwool and wood fibre.

[0009] Both traditional rigid and flexible insulation have well known shortcomings. Rigid insulation mediums are derived from crude oil and are generally combustible. Rockwool, although it is derived from a naturally occurring raw material, is heavy and consumes space.

[0010] The present invention seeks to alleviate the problems associated with known insulation methods.

[0011] Summary of the Invention.

[0012] An object of the present invention is to provide a thermally insulating coating which reduces the transfer of heat through the surface onto which the coating composition has been applied.

[0013] In summary, the present invention relates to the thermally insulating coating compositions which comprise at least from 15% to 80% by weight of a film forming binder, from 10% to 70% by weight of a porous and or non-porous inorganic particles having a D50 particle size range of between 30 pm and 300 pm and a D95 inorganic particle size range of between 2.0 pm and 1000 pm, where the dry weight percentage of the inorganic particles is based upon a dry weight ratio of specific particle size ranges these being a “large” particle size range of between 300 pm to 1000 pm, a “medium” particle size range of between 100 pm to 300 pm, and a “small” particle size range of between 10 pm to 100 pm. The specific ratio of “large” to “medium” to “small” particle size ranges being between 3:2:1 and 3:2:2.

[0014] The coatings derived from the compositions of the invention may be applied by spray, roller or trowel and may be applied to any substrate surface such as wood, metal, masonry, plastics, or composites. Features of the present invention are set out in the appended claims.

[0015] The present invention accordingly provides an air-drying coating composition for applying to a substrate, the coating composition comprising an inorganic porous and inorganic non-porous material having a D50 particle size range of between 30 pm and 300 pm and a D95 particle size range of between 2.0 pm and 1000 pm.

[0016] The coating composition of the present invention has the advantage that when the coating composition is applied to a substrate and allowed to dry, the resulting coating formed on the substrate provides an insulation barrier to the transfer of heat from one side of the coating film to the other side of the coating film.

[0017] Herein, the term “air drying” is understood to mean that the composition comprises water and that the water evaporates after applying the composition to a substrate to form the coating on a substrate.

[0018] The present invention relates to the thermally insulating coating compositions which comprise at least from 15% to 80% by weight of a film forming binder, from 10% to 70% by weight of a porous and or non-porous inorganic particles having a D50 particle size range of between 30 pm and 300 pm and a D95 inorganic particle size range of between 2.0 pm and 1000 pm, where the dry weight percentage of the inorganic particles is based upon a dry weight ratio of specific particle size ranges these being a “large” particle size range of between 300 pm to 1000 pm, a “medium” particle size range of between 100 pm to 300 pm, and a “small” particle size range of between 10 pm to 100 pm. The specific ratio of “large” to “medium” to “small” particle size ranges being between 3:2:1 and 3:2:2.

[0019] The coating compositions of the present invention can be applied to any substrate for example, flexible or rigid, organic, or inorganic substrates. The coatings formed from the compositions of the invention may be applied to the substates by spray, roller or trowel and may be applied to surfaces such as wood, metal, masonry or plastics.

[0020] The thermally insulating coating compositions of the present invention comprise hydrophobized porous and non-porous silica particles, which are either hollow or nano porous, dispersed within a binder.

[0021] The particle size distribution of both the hollow and nano porous silica particles is a critical aspect of the present invention. By combining a selection of hollow and / or nano porous silica particles of a specific particle size distribution in specific weight / volume ratios to one another, combined with the stabilisation of entrained micro-foam, an ultra-high level of particle-to-particle packing has been achieved (as shown in Figure 1 of the accompanying drawings). Accordingly, the transfer of heat through coatings formed from the coating compositions of the present invention is greatly reduced.

[0022] The performance of the coatings of the present invention depends on the pigment volume concentration (PVC), which is a measure of the volume of the silica particles dispersed within the binder. The critical pigment volume concentration (CPVC) refers to the maximum volume of silica particles which can be dispersed within the binder to ensure that all the silica particles are fully surrounded with binder. Typically, if the CPVC is exceeded, the coating will dry to form cracked films. In the present invention, the Applicant has prepared coating films which exceed the CPVC, and the resulting dry films do not crack. This is achieved in accordance with the present invention in that the coating compositions comprise porous and or non-porous inorganic particles of a defined particle size distribution and specific ratios of one particle size distribution to another, which provides intimate particle to particle packing.

[0023] The present invention has the advantage that the coating formed from the coating composition of the present invention provides a solvent free, one or two component thermal insulation coating which has a low thermal conductivity, excellent adhesion to a range of materials, and can air-dry or dry at accelerated temperatures.

[0024] According to the invention, the Applicant has successfully dispersed a range of hydrophobic silica- based particles, which are both porous and non-porous, in a continuous phase comprising binders and additives. The selection of the particle size distribution of both the porous and non-porous materials, the proportional weight of one to the other, together with the combined weight of all porous and non- porous materials in the formulation, allows for the CPVC of the coating to be exceeded while at the same time, producing crack free films.

[0025] The coatings of the present invention, formed from the coating compositions of the present invention, provide an in-situ ambient temperature, thin-film thermal insulation system, which can be applied to both flat and curved organic and inorganic surfaces, using a variety of application techniques.

[0026] The coatings of the present invention have a range of applications including but not limited to the following:

[0027] • Static building insulation.

[0028] • Mobile building insulation for caravans, motor homes etc.

[0029] • Anticondensation coatings for construction applications.

[0030] • Metal pipes for keeping fluids hot or cold.

[0031] • Plastic pipes for keeping fluids hot or cold.

[0032] • Insulation for storage tanks.

[0033] • Safe touch coatings for pipes and radiators.

[0034] • Solar reflective coatings for walls and roofs.

[0035] • Insulative fire-retardant coatings for EV batteries.

[0036] In particular, in relation to the advantage of the compositions of the present invention forming coatings on substrates, it is notable that the coated substrates may have improved fire retardant performance and may function as a fire retardant substrate, for example, a wood panel having a coating formed from the compositions of the present invention may improve the fire performance of a coated wood panel from a Euro class D fire rating to a Euro class C fire rating relative to an uncoated wood panel of the same wood panel type.

[0037] Coating Compositions of the invention:

[0038] The composition may further comprise one of more of the following additives.

[0039] Deionised water.

[0040] Insulation Media.

[0041] The insulating media may be selected from a range of porous and non-porous silica particles which have a low thermal conductivity in the range of 0.012 - 0.050 W / (m.K). The surface area (BET) of the particles may be within the range of 100 m2 / g to 300m2 / g and a tamped density within the range of 40 g / lt to 420 g / lt.

[0042] The porous silica particles as manufactured, are hydrophilic (surface of the particle may be wetted with water). During manufacture, such particles may be hydrophobized, a process during which the surface of the particles is treated with an organofunctional silane, thus rendering the surface of the particle hydrophobic. When dispersed within a liquid, water cannot penetrate the particle, thus the air trapped within the particle, remains intact.

[0043] Polymers

[0044] The selection of the polymer dispersion or polymer solution will depend on the end use application and performance requirements for the coating. The polymer dispersion is a raw material which may comprise acrylic, styrene acrylic, vinyl acetate / vinyl chloride, vinyl acetate / ethylene copolymer, polyurethane, polysiloxanes, silicone, vinyl acetate / VeoVa 10 / acrylate copolymers, polyvinyl acetate, polyvinyl alcohol with varying degrees of polymerisation and hydrolysis or blends thereof.

[0045] Preservative.

[0046] Advantageously, the coating composition will further comprise an in-can preservative and a dry-film preservative, selected from any one or more of the following groups: thiazole, 5-chloro-2-methyl-2H- isothiazol-3-one, 2-dibromo-3-nitropropionamide, oxazine, Hexahydro-1 , 3, 5-tris (2-hydroxyethyl)-s- triazine, 2-Methy l-2H-isothiazol-3-one, dichlorophenyl)-1 , 1 -dimethylurea, 2-Bromo-2-nitropropane-1 ,3- diol, 3-lodo-2-Propynyl butyl carbamate, 5-chloro-2-methyl-4-isothiazolin-3-one, 2-methyl-4- isothiazolin-3-one, 2-n-octyl-4-isothiazolin-3-one, zinc pyrithione, zinc oxide or blends thereof.

[0047] Pigment.

[0048] Advantageously, the coating composition may further comprise a pigment within the family of oxide pigments such as rutile Titanium Dioxide, Iron Oxides or zinc ferrite or blends thereof. Furthermore, the coating may be pigmented with pigment dispersions such as carbon black, arylide, quinophthalone, bismuth vanadate, napthol, quinacridone, dioxazine, phthalocyanine, benzimidazolone, isoindolinone, anthanthrone, ultramarine, DPP, chrome oxides or blends thereof.

[0049] Defoamer.

[0050] Advantageously, the coating composition may further comprise a foam control agent within the family of defoamers selected from one of the following groups, a dispersion of a modified fatty compounds, hydrophobic silica comprising alkoxylate compounds, a polysiloxane dispersion, polysiloxanes, polyether, non-ionic polysiloxane copolymers, non-ionic alkoxylated compounds, silica, and emulsifiers. Surfactant.

[0051] Advantageously, the coating composition will further comprise a surfactant from the family of silane, organomodified siloxane or ammonium polyacrylate.

[0052] Coalescing agent.

[0053] Advantageously, the coating composition may further comprise a coalescing agent, the incorporation of which is dependent on the minimum film forming temperature of the dispersion. The selection of the coalescing agent(s) may be selected from any one or more of the following, Dipropylene Glycol Methyl Ether, Dipropylene Glycol n-Butyl Ether, 2,2,4-Trimethyl-1,3-pentanediol monoisobutyrate, Propylene glycol methyl ether; 1-Methoxy-2-propanol, Ethylene Glycol Phenyl Ether, Ethyl 3-Ethoxypropionate, dicarboxylic acids-diisobutyl ester, mineral spirit 180°C - 200°C, (2-(2-Butoxyethoxy)ethanol), ethylene glycol monobutyl ether acetate or blends thereof.

[0054] Thickener & Rheology Modifier.

[0055] Advantageously, the coating composition will further comprise a thickening agent and / or a rheology modifier which may be selected from any one or more of the following groups, associative alkali swellable emulsions (ASE’s), hydrophobically modified anionic thickeners, non-ionic urethane rheology modifiers, hydroxyethyl cellulose, high-molecular weight polysaccharide, hectorite clay, smectite clay, attapulgite clay, phyllosilicate clay or blends thereof.

[0056] Film Hydrophobicity Additive

[0057] Advantageously, where the coating composition is used in exterior applications, it may further comprise a dispersion of a paraffin wax dispersion.

[0058] Buffer.

[0059] The coating composition may comprise an alkaline pH buffer.

[0060] Advantageously, the alkaline buffer comprises any one or more selected from the following: triethanolamine, dimethylethanolamine, ammonium hydroxide solution, monoethanolamine, 2-amino- 2-methyl-1-propanol used singularly or combined.

[0061] Plasticiser.

[0062] Advantageously, the coating composition may further comprise a plasticiser, which may be selected from one or more of the following, Acetyl Triethyl Citrate, Diisononyl Phthalate, Dioctyl Adipate, Cyclohexane-1.2-Dicarboxylate, or blends thereof.

[0063] Fibres

[0064] The coating composition may comprise film reinforcing fibres. The fibres being composed of fibres. Humectant.

[0065] Advantageously, the coating composition may comprise a humectant comprising of one or more selected from the following: ethylene glycol, propylene glycol, glycerine or blends thereof.

[0066] Corrosion Inhibitor.

[0067] Advantageously, where the coating is applied to metal surfaces, the coating composition may comprise a corrosion inhibitor based on an organic or inorganic salt.

[0068] Air Entraining Agent.

[0069] Advantageously the coating composition may comprise an air entraining agent. The purpose of the air entraining agent is to introduce into the coating a known volume of air. Within the coating, this air is dispersed in the form of micro-foam, which acts as an additional thermal insulator.

[0070] Acknowledgment of Registered Trade Marks

[0071] The following trade marks are registered trade marks: KURRAY, BASF, LOXANOL, ACRONAL, VEOVA, PLEXTOL, SYNTHOMER, ALBERDINGK, BULEY, SILRES, WACKER, VINNAPAS, UNIVAR, REVACRYL, MOWLITH, EVONIK, 3M, ENOVA, KWARK, RHEOLATE, BENAQUA, ELEMENTIS, BENTONE, VINAPOR, AGITAN, MUNZING, DOAWANOL, DOW CHEMICAL, DISPEX, COATOSIL, ACTICIDE, ARBOCEL, TIOXIDE, BAYFERROX, LUCONYL, ASCOTRAN, PALATINOL, HEXAMOLL, COLORTHERM, LANXESS.

[0072] Raw Materials & Suppliers

[0073] Deionised Water, in an amount of between 4.9 % and 43.80 % (w / w).

[0074] Kuraray Poval 3-83, a water-soluble, partially saponified, polyvinyl alcohol (PVOH) grade manufactured by Kuraray Europe GmbH, Frankfurt, Germany.

[0075] Kuraray Poval 4-88, a water-soluble, partially saponified, polyvinyl alcohol (PVOH) grade manufactured by Kuraray Europe GmbH, Frankfurt, Germany.

[0076] Loxanol Ml 6840, a paraffin wax dispersion having a solids content of 63%, manufactured by BASF, Ludwigshafen, Germany.

[0077] Acronal PRO 770, a styrene acrylic polymer dispersion, having a solids content of 50% and a minimum film forming temperature (MFFT) of 19°C, manufactured by BASF, Ludwigshafen, Germany.

[0078] Plextol R5530, a VeoVa / Acrylic copolymer dispersion polymer dispersion, having a solids content of 46% and a minimum film forming temperature (MFFT) of 19°C, manufactured by Synthomer Deutschland, Marl, Germany.

[0079] AlberdingkAC 2403, an acrylic polymer dispersion having a solids content of 47% and a minimum film forming temperature (MFFT) of 16°C, manufactured by Alberdingk Boley GmbH, Krefeld, Germany.

[0080] CHP 517, a styrene acrylic polymer dispersion having a solids content of 60% and a minimum film forming temperature (MFFT) of 0°C, manufactured by CH Polymers Oy, Kaipiainen, Finland.

[0081] CHP 5176.5 EP, a styrene acrylic polymer dispersion having a solids content of 50% and a minimum film forming temperature (MFFT) of 24°C, manufactured by CH Polymers Oy, Kaipiainen, Finland.

[0082] Coatosil DRI, a silicone dispersion having a solids content of 45%, manufactured by Momentive Performance Materials

[0083] Silres BS1306 a, silicone dispersion having a solids content of 55%, manufactured by Wacker Chemie AG, Berghausen, Germany.

[0084] Vinnapas 822HD, a polymer dispersion having a solids content of 60% and a minimum film forming temperature (MFFT) of 7°C, manufactured by Wacker Chemie AG, Berghausen, Germany.

[0085] Vinnapas 240 HD, a polymer dispersion having a solids content of 50% and a minimum film forming temperature (MFFT) of 0°C, manufactured by Wacker Chemie AG, Berghausen, Germany.

[0086] Vinnapas 224 HD, a polymer dispersion having a solids content of 50% and a minimum film forming temperature (MFFT) of 12°C, manufactured by Wacker Chemie AG, Berghausen, Germany.

[0087] Acronal S790, a polymer dispersion having a solids content of 50% and a minimum film forming temperature (MFFT) of 20°C, manufactured by BASF, Ludwigshafen, Germany.

[0088] Sodium Silicate 47 / 48, a sodium silicate solution having a solids content of 43% and a silica to alumina (SiO2 / AIK2O) of 2.70, supplied by Univar Ireland Ltd, Rathcoole Dublin

[0089] Revacryl AE 3826, a styrene acrylic polymer dispersion having a solids content of 50% and a minimum film forming temperature (MFFT) of 4°C, manufactured by Synthomer Germany GmbH.

[0090] Revacryl AE 3820, a styrene acrylic polymer dispersion having a solids content of 50% and a minimum film forming temperature (MFFT) of 4°C, manufactured by Synthomer Germany GmbH. Mowilith LDM 1829, a polymer dispersion of vinyl acetate, methacrylic acid esters, vinyl esters and ethylene, having a solids content of 50% and a minimum film forming temperature (MFFT) of 0°C, manufactured by Celanese, Frankfurt, Germany.

[0091] Mowilith LDM 1869, a polymer dispersion of vinyl acetate, ethylene and methacrylic acid esters, having a solids content of 53% and a minimum film forming temperature (MFFT) of 1°C, manufactured by Celanese, Frankfurt, Germany.

[0092] Mowilith LDM 2301 , a polymer dispersion of vinyl acetate / vinyl ester polymer, having a solids content of 50% and a minimum film forming temperature (MFFT) of 13°C, manufactured by Celanese, Frankfurt, Germany.

[0093] Mowilith LDM 6119, a polymer dispersion of styrene acrylic having a solids content of 50% and a minimum film forming temperature (MFFT) of 1°C, manufactured by Celanese, Frankfurt, Germany.

[0094] Mowilith LDM 7709, a polymer dispersion of an acrylic polymer, having a solids content of 46% and a minimum film forming temperature (MFFT) of 2°C manufactured by Celanese, Frankfurt, Germany.

[0095] Mowilith LDM 7719, a polymer dispersion of an acrylic, methacrylic acid polymer having a solids content of 50% and a minimum film forming temperature (MFFT) of 1°C manufactured by Celanese, Frankfurt, Germany.

[0096] Fillocell 140H, a hollow mineral-based silica having an average D50 particle size of 50 - 60 pm, and a tamped density of 100 to 150 g / lt, manufactured by Nordisk Perlite, Hillenad, Denmark.

[0097] GS32, a hollow mineral-based silica having an average D50 particle size of 55 pm, and a tamped density of 300 - 340 g / lt, manufactured by Sinosteel Maanshan Institute of Mining Research Company Ltd, Anhui, China.

[0098] GS40, a hollow mineral-based silica having an average D50 particle size of 50pm, and a tamped density of 380 - 420 g / lt manufactured by Sinosteel Maanshan Institute of Mining Research Company Ltd, Anhui, China.

[0099] GS46, a hollow mineral-based silica having an average D50 particle size of 50pm, and a tamped density of 440 - 480 g / lt manufactured by Sinosteel Maanshan Institute of Mining Research Company Ltd, Anhui, China.

[0100] Tego Therm HPG 4000, a porous mineral-based silica having an average D50 particle size of 300 pm, and a tamped density of 225 g / lt, manufactured by Evonik Operations GmbH, Essen, Germany.

[0101] Tego Therm HPG 6806, a porous mineral-based silica having an average D50 particle size of 30pm, and a tamped density of 300 g / lt, manufactured by Evonik Operations GmbH, Essen, Germany.

[0102] S28HS, a hollow mineral-based silica having an average particle size of 30pm, and a tamped density of 280 g / lt, manufactured by 3M Advanced Materials, Minnesota, USA.

[0103] Enova IC3100, a hollow mineral-based silica having a particle size range of 2 - 40 pm, and a tamped density of 120 - 150 g / lt, manufactured by Cabot Aerogel, Frankfurt, Germany.

[0104] Kwark XP100, a porous mineral-based silica having an average D95 particle size of 10 - 100 pm, and a tamped density of 50 - 100 g / lt, manufactured by Enersens, Bourgoin-Jallieu, France.

[0105] Kwark XP200, a porous mineral-based silica having an average D95 particle size of 10 - 200 pm, and a tamped density of 50 - 100 g / lt, manufactured by Enersens, Bourgoin-Jallieu, France. Kwark XP500, a porous mineral-based silica having an average D95 particle size of 10 - 500 pm, and a tamped density of 50 - 100 g / lt, manufactured by Enersens, Bourgoin-Jallieu, France.

[0106] Xanthan Gum TG, a high molecular weight polysaccharide thickener manufactured by Jungbunzlauer, Basel, Switzerland.

[0107] Xanthan Gum TN, a high molecular weight polysaccharide thickener manufactured by Jungbunzlauer, Basel, Switzerland.

[0108] Xanthan Gum TNP, a high molecular weight polysaccharide thickener manufactured by Jungbunzlauer, Basel, Switzerland.

[0109] Xanthan Gum FFST, a high molecular weight polysaccharide thickener manufactured by Jungbunzlauer, Basel, Switzerland.

[0110] Rheolate 125, an acrylic alkaline rheological additive manufactured by Elementis GmbH, Cologne, Germany.

[0111] Benaqua 4000, a high molecular weight polysaccharide rheological additive manufactured by Elementis GmbH, Cologne, Germany.

[0112] Bentone DY-CE, an organically modified and beneficiated smectite clay rheological additive manufactured by Elementis GmbH, Cologne, Germany.

[0113] Vinapor AE 3914, a surfactant air entraining agent manufactured by BASF, Ludwigshafen, Germany.

[0114] Agitan 120, a dispersion of modified fatty compounds, hydrophobic silica, alkoxylated compounds, polysiloxane copolymer, defoamer, manufactured by Munzing Chemie Gmbh, Abstatt, Germany.

[0115] Agitan 158, a dispersion of organic modified polysiloxanes defoamer, manufactured by Munzing Chemie Gmbh, Abstatt, Germany.

[0116] Agitan 351 , a dispersion emulsion of a modified fatty and alkoxylated compounds, silica defoamer, manufactured by Munzing Chemie Gmbh, Abstatt, Germany.

[0117] Agitan 762, a dispersion of a Blend of a modified polysiloxanes defoamer, manufactured by Munzing Chemie Gmbh, Abstatt, Germany.

[0118] Dowanol DPM, a Dipropylene Glycol Methyl Ether coalescing agent manufactured by Dow Chemicals, Michigan, USA.

[0119] Coatosil 1211C, a siloxane surfactant manufactured Momentive Performance Materials, New York, USA.

[0120] Dispex AA 4040 , an ammonium polyacrylate surfactant manufactured by BASF, Ludwigshafen, Germany.

[0121] Acticide CHR 0107, an in-can paint preservative based on CIT / MIT and Bronopol. Manufactured by Thor Chemicals UK.

[0122] Acticide IPA 20, a dry film preservative based on 3-iodo-2-propynylbutylcarbamate, for use when the TIPS is applied directly to wood. Manufactured by Thor Chemicals UK.

[0123] Arbocell BE 600-30 PU, a cellulose reinforcing fibre having an average fibre length of 40 pm and an average fibre width of 20 pm, manufactured by J. Rettenmaier, Germany.

[0124] Tioxide TR 92, a white pigment manufactured by TRiiSO, Billingham, England.

[0125] Bayferrox 130 M, a red pigment manufactured by Lanxess, Krefeld-Uerdingen, Germany.

[0126] Bayferrox 318 MB a black pigment manufactured by Lanxess, Krefeld-Uerdingen, Germany. Bayferrox 3920, a yellow pigment manufactured by Lanxess, Krefeld-Uerdingen, Germany.

[0127] Colortherm yellow 30, a Zinc Ferrite Pigment. Manufactured by Lanxess, Krefeld-Uerdingen, Germany. Luconyl Organic Pigments. Manufactured by Sun Chemicals.

[0128] Nalzin FA 179. Azinc-based corrosion inhibitor manufactured by Elementis, Cologne, Germany. Nalzin FA 579. Azinc-based corrosion inhibitor manufactured by Elementis, Cologne, Germany. Ascotran H10. An organic salt rust inhibitor manufactured by Ascotec, Saint-Etienne, France.

[0129] Ascotran H14. An organic salt rust inhibitor manufactured by Ascotec, Saint-Etienne, France. Ascotran HPB. An organic salt rust inhibitor manufactured by Ascotec, Saint-Etienne, France. Monopropylene glycol, a drying time extender (humectant). Various suppliers.

[0130] Palatinol N, a phthalate plasticiser manufactured by BASF, Ludwigshafen, Germany.

[0131] Hexamoll DINCH, a cyclohexane-1.2-dicarboxylate plasticiser manufactured by BASF, Ludwigshafen, Germany.

[0132] The coating composition of the present invention comprises a solid phase (the porous / nonporous, silica / non-silica-based insulating media), dispersed within a continuous phase (the binder) which is selected from a range polymer dispersions and polymer solutions.

[0133] Provided herein is an example of a typical method / procedure for the manufacture of the coating composition. This example of the method for forming the coating compositions of the present invention is provided by way of a general example only.

[0134] The coating composition is preferably produced in a circular stainless steel or high-density polyethylene mixing vessel. The mixing blade is a standard non-toothed impellor type, approx. 2.5 times smaller than the internal diameter of the mixing vessel. a. The mixer is charged with all the deionised water and siloxane surfactant, then switched on to an impellor rotational speed of typically 250 RPM. b. After two minutes, the preservative is added and if required, the foam control agent. c. After two minutes, the binder is added, and the mixer speed is increased to 350 RPM. d. The porous / nonporous, silica / non-silica-based materials are incorporated slowly and individually in that the solid raw materials are added in a fashion that more solid raw material is not incorporated until and the previous addition has been fully dispersed within the binder. The optimum use of impellor rotational speed is critical, only sufficient speed to maintain a functional vortex. e. Following dispersion of all the insulation media within the composition, the remaining raw materials are added, maintaining impellor rotation speed of between 800 RPM and 1200 RPM.

[0135] Optimum mixing speed range: 250 RPM (start) to 1200 RPM (finish).

[0136] Optimum mixing temperature: Not higher than 25°C.

[0137] Optimum dispersion time: 20 to 40 minutes (batch size dependent). The present invention will now be described, by way of example only, several embodiments of the invention, with reference to the following specific Examples and with reference to the accompanying Figure in which is shown:

[0138] Figure 1 is as Scanning Electron Microscopy (SEM) Photograph showing packing of hollow and porous silica materials in a coating in accordance with the present invention, which coating is formed from the coating composition of the present invention.

[0139] Example 1 , (DP10137) Thermal Conductivity W / m / K 0.0422.

[0140] This is an example of the present invention in which a porous hydrophobic silica is dispersed within a mixture of water and an unplasticized solvent free internally cross linked 60% solids styrene acrylic copolymer dispersion stabilized with an anionic emulsifying system. This coating is designed for use on engineered wood substrates including all types of panels or wood products and masonry surfaces.

[0141] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After two minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D followed by raw material E, over a combined addition time of ten minutes. Maintain a vortex and where necessary, increase the impellor rotational speed to 1000 RPM. Add the 2% solution of raw material F and allow to mix for five minutes, increasing the impellor rotational speed to maximum 1,000 RPM if required. Decant.

[0142] Example 2, (DP10139) Thermal Conductivity W / m / K 0.0456.

[0143] This is an example of the present invention in which a nano-porous hydrophobic silica is dispersed within a mixture of water and a hard, unplasticized 50% solids styrene acrylic copolymer dispersion stabilized with an anionic emulsifying system, using dipropylene glycol methyl ether. This coating is designed for use on masonry surfaces or other rigid surfaces.

[0144] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After two minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D followed by raw material E, over a combined addition time of ten minutes. Maintain a vortex and where necessary, increase the impellor rotational speed to 1000 RPM. Add the 2% solution of raw material F and allow to mix for five minutes. Add raw material G, increasing the impellor rotational speed to maximum 1 ,200 RPM if required. Decant

[0145] Example 3, (DP10150) Thermal Conductivity W / m / K 0.0473.

[0146] This is an example of the present invention in which a nano-porous hydrophobic silica is dispersed within a mixture of water, a siloxane surfactant and a hard, unplasticized 50% solids styrene acrylic copolymer dispersion stabilized with an anionic emulsifying system and using dipropylene glycol methyl ether as a coalescing agent. This hard coating is designed for use on masonry surfaces or other rigid surfaces.

[0147] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D. After two minutes mixing, add raw material E followed by raw material F, over a combined addition time of ten minutes. Maintain a vortex and where necessary, increase the impellor rotational speed to 1000 RPM. Add the 2% solution of raw material G and allow to mix for five minutes. Add raw material H, increasing the impellor rotational speed to maximum 1 ,200 RPM if required. Decant

[0148] Example 4, (DP10152) Thermal Conductivity W / m / K 0.0395.

[0149] This is an example of the present invention in which a nano-porous hydrophobic silica is dispersed within a mixture of water and a surfactant, and a 60% solids styrene acrylic copolymer dispersion stabilized with an anionic emulsifying system. This flexible coating is designed for use on masonry surfaces or other rigid surfaces where crack bridging is a requirement.

[0150] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D. After two minutes mixing, add raw material E followed by raw material F, over a combined addition time of ten minutes. Maintain a vortex and where necessary, increase the impellor rotational speed to 1000 RPM. Add the 2% solution of raw material G and allow to mix for five minutes, increasing the impellor rotational speed to maximum 1 ,200 RPM if required. Decant

[0151] Example 5,

[0152] This is an example of the present invention in which a nano-porous hydrophobic silica is dispersed within a mixture of water and a surfactant, and a 50% solids styrene acrylic copolymer dispersion stabilized with an anionic emulsifying system and thickened with a smectite clay. This coating is designed for use on internal or external masonry surfaces where the surface may be damp, or humidity is high.

[0153] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D followed by raw material E, over a combined addition time of ten minutes. Maintain a vortex and where necessary, increase the impellor rotational speed to 1000 RPM. Add the 4.5% solution of raw material F and allow to mix for five minutes. Add raw material G and allow to mix for five minutes, followed by raw material H, increasing the impellor rotational speed to maximum 1 ,200 RPM if required. Decant

[0154] Example 6,

[0155] In this example of the present invention, a coating for application onto exterior masonry surfaces, based upon a polymer dispersion of vinyl acetate, ethylene and methacrylic acid esters, comprising a coalescing agent. This coating is designed for use on exterior masonry or interior cavity masonry coatings.

[0156] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D followed by raw material E, over a combined addition time of ten minutes. Maintain a vortex and where necessary, increase the impellor rotational speed to 1000 RPM. Add the 4.5% solution of raw material F and allow to mix for five minutes. Add raw material G and allow to mix for five minutes, followed by raw material H, increasing the impellor rotational speed to maximum 1 ,200 RPM if required. Decant.

[0157] Example 7,

[0158] This is an example of the present invention which is a thermally insulating coating which comprises both nano-porous hydrophobic silica and non-porous, hollow spheres made from soda-lime borosilicate glass, dispersed in a styrene / acrylic acid ester copolymer. This coating is designed for use on internal or external masonry surfaces where the surface may be damp, or humidity is high.

[0159] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D. Allow to mix until raw material D has been fully incorporated following which, add raw material E, again allowing to mix until raw material E has been fully incorporated. Add raw material F and again allow it to be fully incorporated. Add the 3.0 % solution of raw material G and allow to mix for five minutes. Throughout the addition of raw materials D, E and F, the rotational speed of the impellor must be very gradually increased to the minimum to maintain a vortex. Throughout mixing, rotational impellor speed should not exceed 1 ,000 rpm.

[0160] Example 8,

[0161] In this example, an ambient thermally insulating solar reflective roof and / or wall coating is prepared using a combination of nen-porous hollow spheres made from soda-lime borosilicate glass and the inclusion of a pigment which scatters radiation.

[0162] Manufacturing Procedure: Charge the mixer with A. switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D and allow to mix for two minutes. Slowly add raw material E and correspondingly increasing impellor rotational speed to 800 RPM. Allow to disperse until a Hegman 8 pigment fineness of grind has been obtained. Following pigment grinding, reduce impellor rotational speed to 600 RPM and slowly add raw material F followed by raw material G. Modify impellor speed to maintain a vortex. Five minutes following the addition of raw material G, add the 4.761 % solution of raw material H. Example 9,

[0163] This is an example of the present invention which is a thermally insulating coating which comprises both nano-porous hydrophobic silica and non-porous, hollow spheres made from soda-lime borosilicate glass, dispersed in a styrene / acrylic acid ester copolymer acrylic / methacrylic acid polymer. Designed for application onto structural wood panels.

[0164] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D and allow to mix for two minutes. Add raw material E, followed by raw material F and raw material G. Modify the impellor speed to maintain a vortex. And where necessary, increase the impellor rotational speed to 1000 RPM. Add the 4.761 % solution of raw material H and allow to mix for five minutes.

[0165] Example 10,

[0166] This is an example of the present invention which is a thermally insulating coating which comprises both nano-porous hydrophobic silica and non-porous, hollow spheres made from soda-lime borosilicate glass, dispersed in a styrene / acrylic acid ester copolymer acrylic / methacrylic acid polymer. Designed for application onto external masonry and mineral surfaces. Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D and allow to mix for two minutes. Add raw material E, followed by raw material F and raw material G. Modify the impellor speed to maintain a vortex. And where necessary, increase the impellor rotational speed to 1200 RPM. Add the 4.761 % solution of raw material H and allow to mix for five minutes.

[0167] Example 11 ,

[0168] This is an example of the present invention which is a thermally insulating coating which comprises both nano-porous hydrophobic silica and non-porous, hollow spheres made from soda-lime borosilicate glass, dispersed in a styrene / acrylic acid ester copolymer a polymer dispersion of vinyl acetate, methacrylic acid esters, vinyl esters and ethylene. Designed for application onto internal wood surfaces.

[0169] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D and allow to mix for two minutes. Add raw material E, followed by raw material F and raw material G. Modify the impellor speed to maintain a vortex. And where necessary, increase the impellor rotational speed to 1200 RPM. Add the 4.761 % solution of raw material H and allow to mix for five minutes.

[0170] Example 12,

[0171] This is an example of the present invention which is a thermally insulating coating which comprises both nano-porous hydrophobic silica and non-porous, hollow spheres made from soda-lime borosilicate glass, dispersed in a styrene / acrylic acid ester copolymer. Designed for application onto rigid or flexible plastic or composite substrates.

[0172] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D and allow to mix for two minutes. Add raw material E, followed by raw material F and raw material G. Modify the impellor speed to maintain a vortex. And where necessary, increase the impellor rotational speed to 1200 RPM. Add the 4.761 % solution of raw material H and allow to mix for five minutes.

[0173] Example 13,

[0174] This is an example of the present invention which is a thermally insulating coating which comprises both nano-porous hydrophobic silica and non-porous, hollow spheres made from soda-lime borosilicate glass, dispersed in an acrylic dispersion. Designed for use on ferrous metal pipes.

[0175] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D and allow to mix for five minutes. Add raw material E followed by raw material F, G and H. During the addition of raw material G, ensure that it is added slowly and over a period of five minutes. Modify the impellor speed to maintain a vortex. And where necessary, increase the impellor rotational speed to 1200 RPM. Slowly add raw material I followed by J and allow to mix for five minutes. Example 14,

[0176] This is an example of the present invention which is a hydrophobic thermally insulating coating which comprises both nano-porous hydrophobic silica and non-porous, hollow spheres made from soda-lime borosilicate glass, dispersed in a styrene / acrylic acid ester copolymer. This coating is designed for application onto internal and external masonry surfaces where a high degree of water repellence is required.

[0177] Manufacturing Procedure: Charge the mixer with A. switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After five minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D and allow to mix for two minutes. Slowly add raw material E followed by raw material F and raw material G. During the addition of raw materials F, G and H, the impellor rotation speed will need to be gradually increased to maintain a vortex. Add raw material H (a slight thickening of the coating will be observed). Add raw material I and allow to mix for five minutes. Add the 4.761 % solution of raw material J and allow to mix for ten minutes.

[0178] Example 15,

[0179] This is an example of the present invention in which a porous hydrophobic silica is dispersed within a mixture of water and an unplasticized solvent free internally cross linked 60% solids styrene acrylic copolymer dispersion stabilized with an anionic emulsifying system. The coating is designed for application onto metal pipes and panels and can be used to insulate heating pipes or panels used to manufacture ‘white goods’ such as ovens and fridges / freezers.

[0180] Manufacturing Procedure: Charge the mixer with A, switch on mixer to achieve an impellor rotational speed of 250 RPM. After two minutes mixing, add raw material B. After two minutes, add raw material C and increase impellor rotational speed to 350 RPM. After two minutes mixing, add raw material D. Over a ten-minute period, add raw material E followed by raw material F. During the slow addition of E and F, increase impellor speed to a maximum of 1 ,000 PRM maintain a vortex. Add the 2% solution of raw material G and allow to mix for five minutes, increasing the impellor rotational speed to maximum 1,200 RPM. Finally add raw material H. During addition of raw material H, a speed reduction down to approx, range 800 to 1000 RPM is optimum.

Claims

Claims1. An air-drying, thermally insulating coating composition for applying to a substrate, the coating composition comprising at least from 15% to 80% by weight of a film forming binder, from 10% to 70% by weight of an inorganic porous and inorganic non-porous hydrophobic particles having a D50 particle size range of between 30 pm and 300 pm and a D95 inorganic particle size range of between 2.0 pm and 1000 pm, where the dry weight percentage of the inorganic particles is based upon a dry weight ratio of specific particle size ranges, being a “large” particle size range of between 300 pm to 1000 pm, a “medium” particle size range of between 100 pm to 300 pm, and a “small” particle size range of between 10 pm to 100 pm; and wherein the ratio of “large” to “medium” to “small” particle size ranges is in a ratio of between 3:2:1 and 3:2:2, whereby after applying the coating composition to a substrate, the coating composition forms a coating film and provides an insulation barrier to the transfer of heat from one side of the coating film to the other side of the coating film.

2. A coating composition as claimed in claim 1 comprising an air entraining agent.

3. A coating composition as claimed in claim 2 wherein the air entraining agent is a sodium salt of C14-16 Olefin sulphonate.

4. A coating composition as claimed in claims 2 or 3 wherein the air entraining agent is Sodium dodecyl sulphate.

5. A coating composition claimed in any one of claims 2 to 4 wherein the air entraining agent is present in the amount from 0.01 % to 0.5 %.

6. A coating composition claimed in any one of claims 1 to 45 comprising a siloxane surfactant.

7. A coating composition claimed in claim 46 wherein the siloxane surfactant is present in an amount from 0.01 % to 3.0 % (w / w).

8. A coating composition claimed in claim 1 where inorganic porous and inorganic non-porous materials are based on a silica.

9. A coating composition claimed in claim 8 wherein the inorganic silica material is porous.

10. A coating composition claimed in any one of claims 1 to 9 wherein the inorganic material is non-porous.

11. A coating composition claimed in any one of claims 1 to 10 wherein the particle size range of the inorganic porous and non-porous materials is in the range from 2.0 pm to 600 pm.

12. A coating composition claimed in any one of claims 1 to 11 wherein the particle size range of the inorganic porous and inorganic non-porous materials are within the range from 2 .0 pm to 500 pm.

13. A coating composition as claimed in any one of claims 1 and 12 wherein the weight of the inorganic porous or non-porous hydrophobic material is between 10.00 % and 70.0 % (w / w) of the total coating composition.

14. A coating composition as claimed in any one of claims 1 and 13 wherein the weight of the inorganic porous or non-porous hydrophobic material is preferably between 25.00 % and 55.00 % (w / w) of the total coating composition.

15. A coating composition claimed as in any preceding claim wherein the binder included in the coating composition in an amount of 15.00 % to 80.00 % (w / w).

16. A coating composition as claimed in any preceding claimwherein the binder is preferably included in the coating composition in an amount of 20.00 % to 70.00 % (w / w).

17. A coating composition as claimed in any preceding claim wherein the binder is most preferably included in the coating composition in an amount of 30.00 % to 50.00 % (w / w).

18. A coating composition as claimed in any preceding claim wherein the binder has a Minimum Film Forming Temperature (MFFT ) within the range of -35°C to +70°C.

19. A coating composition as claimed in any preceding claim wherein the binder has a Minimum Film Forming Temperature (MFFT ) of preferably within the range of -5°C to +60°C.

20. A coating composition as claimed in any preceding claim wherein the binder has a Minimum Film Forming Temperature (MFFT ) of most preferably within the range of 0°C to +30°C.

21. A coating composition as claimed in any preceding claim wherein the binder is an acrylic binder.

22. A coating composition as claimed in claim 21wherein the binder is an acrylic dispersion.

23. A coating composition as claimed in any one of claims 1 to 20wherein the binder is a silicone binder.

24. A coating composition as claimed in claim 23wherein the binder is a silicone dispersion.

25. A coating composition as claimed in any one of claims 1 to 20wherein the binder is a styrene acrylic binder.

26. A coating composition as claimed in claim 25wherein the binder is a styrene acrylic dispersion.

27. A coating composition as claimed in any one of claims 1 to 20 wherein the binder is a vinyl acetate / vinyl chloride binder.

28. A coating composition as claimed in claim 27wherein the binder is a vinyl acetate / vinyl chloride dispersion.

29. A coating composition as claimed in any one of claims 1 to 20 wherein the binder is a vinyl acetate / ethylene copolymer binder.

30. A coating composition as claimed in claim 29 wherein the binder as a vinyl acetate / ethylene copolymer dispersion.

31. A coating composition as claimed in any one of claims 1 to 20 wherein the binder as a polyurethane binder.

32. A coating composition as claimed in claim 31wherein the binder is a polyurethane dispersion.

33. A coating composition as claimed in any one of claims 1 to 20 wherein the binder is a vinyl acetate / VeoVa 10 / acrylic binder.

34. A coating composition as claimed in claim 33wherein the binder is a vinyl acetate / VeoVa 10 / acrylic dispersion.

35. A coating composition as claimed in any one of claims 1 to 20 wherein the binder as a polyvinyl acetate binder.

36. A coating composition as claimed in claim 35wherein the binder as a polyvinyl acetate dispersion.

37. A coating composition as claimed in claims 1 to 20 wherein the binder as a polyvinyl alcohol binder.

38. A coating composition as claimed in claim 37wherein the binder is a polyvinyl alcohol solution.

39. A coating composition as claimed in claims 1 to 20 wherein the binder is a sodium silicate solution.

40. A coating composition in claim in any preceding claim wherein a thickener is present in an amount from 0.01% to 2.0% (w / w).

41. A coating composition in claimed in claim 40wherein the thickener is a high molecular weight polysaccharide.

42. A coating composition claimed in any preceding claim wherein a rheology modifier is present in an amount from 0.01% to 2.0% (w / w)43. A coating composition claimed in claim 42wherein the rheology modifier is a salt of an acrylic copolymer.

44. A coating composition claimed in any preceding claim wherein a humectant is present in an amount of 0.5% to 5.0 %.

45. A coating composition claimed in claim 44wherein the humectant is a diol.

46. A coating composition claimed in claim 45wherein the diol is monopropylene glycol.

47. A coating composition as claimed in any one of the preceding claims wherein the composition comprises a paraffin wax dispersion.

48. A coating composition claimed in claim 47 wherein the paraffin wax dispersion is present in an amount of 0.5% to 2.0%.

49. A coating composition claimed in any preceding claimcomprising reinforcing fibre in an amount of from 0.1% to 3.0% (w / w).

50. A coating composition claimed in claim 49 wherein the reinforcing fibre length ranges from 10 pm to 100 pm.51 . A coating composition claimed in any one of claims 49 or 50wherein the reinforcing fibre length ranges most preferably between 30 pm to 50 pm.

52. A coating composition claimed in any preceding claim comprising a coalescing agent.

53. A coating composition claimed in claim 52 wherein the coalescing agent is present in an amount from 2.0 % to 6.0 %.

54. A coating composition claimed in claims 52 or 53 wherein the coalescing agent is a glycol ether.

55. A coating composition claimed in claims 52 to 54 wherein the coalescing agent is dipropylene glycol methyl ether.

56. A coating composition claimed in any preceding claim comprising a defoamer.

57. A coating composition claimed in claim 56 wherein the defoamer is present in an amount of 0.1% to 2.0%.

58. A coating composition claimed in claims 56 or 57 wherein the defoamer is a non-ionic polysiloxane copolymers.

59. A coating composition claimed in any preceding claim comprising a plasticiser.

60. A coating composition claimed in claim 59 wherein the plasticiser is present in an amount from 2.0% to 6.0% (w / w).

61. A coating composition claimed in claims 59 or 60 wherein the plasticiser is a di-isononyl ester of 1-2, cyclohexanedicarboxylic acid.

62. A coating composition claimed in any preceding claim comprising a corrosion inhibitor.

63. A coating composition claimed in claim 62 wherein the corrosion inhibitor is a complex zinc compound.

64. A coating composition claimed in claims 62 or 63 wherein the corrosion inhibitor is present in an amount of 0.1% to 2.0 % (w / w).

65. A coating composition claimed in any one of claims 1 to 56 comprising an alkaline buffer.

66. A coating composition claimed in claim 65 wherein the alkaline buffer is present in an amount from 0.1 % to 3.0%67. A coating composition claimed in any one of claims 65 or 66 wherein the alkaline buffer is ammonium hydroxide solution (specific gravity 0.880 g / ml).

68. A coating composition claimed in any preceding claim comprising an in-can preservative.

69. A coating composition claimed in any one of claims 1 to 60comprising a dry film preservative.

70. A coating formed from the coating composition as claimed in any preceding claim.

71. A coating system comprising a substrate and a coating formed from the coating composition as claimed in any preceding claim.

72. A coating system as claimed in claim 71 wherein the substrate comprises wood, metal, masonry, plastics or composite materials.

73. A coating system as claimed in claim 72 wherein the wood comprises virgin wood or engineered wood including all types of panels formed from wood and wood products formed by processing from flakes or chips.

74. A coating system as claimed in claim 73 wherein the wood comprises Medium-density fibreboard (MDF) or oriented strand board (OSB).

75. A method of coating a substrate surface comprising applying a coating composition as claimed in any claims 1 to 69.

76. A method as claimed in claim 75 wherein the coating composition is applied by any possible method including roller, spray, trowel, curtain coater or extrusion technique.

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