Claims:1. A coating composition comprising:
a) Component-A comprising-
1. Oxidizer dispersion;
2. Surfactant dispersion; and
3. Solvent
b) Component-B comprising-
1. the Component-A;
2. Solvent; and
3. Surfactant dispersion
c) Component-C comprising-
1. Silane derivative selected from a group comprising mixture of 3- glycidoxy propyl trimethoxy silane and timethoxy silane; mixture of 3-glycidoxy propyl trimethoxy silane, methyl trimethoxy silane and vinyl trimethoxy silane; mixture of 3- glycidoxy propyl trimethoxy silane and methyl trimethoxy silane;
mixture of 3- glycidoxy propyl trimethoxy silane and triethyl phosphate; mixture of methyl trimethoxy silane and vinyl trimethoxy silane; mixture of 3 glycidoxy propyl trimethoxy silane, tri ethyl phosphate and methyl trimethoxy silane; and mixture of 3 glycidoxy propyl trimethoxy silane, tri ethyl phosphate, methyl trimethoxy silane and vinyl trimethoxy silane.
2. Polypropylene dispersion;
3. Polyethylene dispersion;
4. Acrylic polymer;
5. Solvent; and
6. Additive.

2. The coating composition as claimed in claim 1, wherein the oxidizer dispersion of the Component-A is selected from a group comprising mixture of about 3wt.% to 7wt.% of digallic acid, about 22wt.% to 28wt.% of butyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid; mixture of about 3wt.% to 7wt.% of digallic acid, about 22wt.% to 28wt.% of ethyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid; mixture of about 3wt.% to 7wt.% m-trigallic acid, about 22wt.% to 28wt.% of butyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid; and mixture of about 3wt.% to 7wt.% of m-trigallic acid, about 22wt.% to 28wt.% of ethyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid.

3. The coating composition as claimed in claim 1, wherein the surfactant dispersion of the Component-A is selected from a group comprising about 0.3wt.% to 0.5wt.% of non-ionic fluorosurfactant, about 0.3wt.% to 0.5wt.% of dialkyl sulphosuccinate, about 0.3wt.% to 0.5wt.% of branched hydrocarbon surfactant and any combination thereof.

4. The coating composition as claimed in claim 1, wherein the solvent of the Component-A is selected from a group comprising about 30wt.% to 40wt.% of demineralized water.

5. The coating composition as claimed in claim 1, wherein the solvent of the Component-B is selected from a group comprising about 25wt.% to 35wt.% of iso-propyl alcohol, about 25wt.% to 35wt.% of ethanol, mixture of isopropyl alcohol and ethanol at a ratio of about 3:1, about 15wt.% to 30wt.% of demineralized water and any combination thereof.

6. The coating composition as claimed in claim 1, wherein the surfactant dispersion of the Component-B is selected from a group comprising mixture of about 3wt.% to 5wt.% of manganese phosphate, about 1.5wt.% to 2.5wt.% of manganese sulphate, about 0.03wt.% to 0.05wt.% of quaternary ammonium surfactant and about 10wt.% to 25wt.% of phosphoric acid; and mixture of about 3wt.% to 5wt.% manganese phosphate, about 1.5wt.% to 2.5wt.% of manganese sulphate, about 1.5wt.% to 2.5wt.% of nickel sulphate, about 0.03wt.% to 0.05wt.% of quaternary ammonium surfactant and about 10wt.% to 25wt.% of phosphoric acid.

7. The coating composition as claimed in claim 1, wherein the Component-B comprises about 15wt.% to 20wt.% of the Component-A.

8. The coating composition as claimed in claim 1, wherein the silane derivative of the Component-C is selected from a group comprising mixture of about 7wt.% to 10wt.% of 3- glycidoxy propyl trimethoxy silane and about 7wt.% to 10wt.% of trimethoxy silane; mixture of about 7wt.% to 10wt.% of 3-glycidoxy propyl trimethoxy silane, about 7wt.% to 10wt.% of methyl trimethoxy silane and about 7wt.% to 10wt.% of vinyl trimethoxy silane; mixture of about 7wt.% to 10wt.% of 3- glycidoxy propyl trimethoxy silane and about 7wt.% to 10wt.% of methyl trimethoxy silane; mixture of about 7wt.% to 10wt.% of 3- glycidoxy propyl trimethoxy silane and about 7wt.% to 10wt.% of triethyl phosphate; mixture of about 3 wt.% to 10wt.% of methyl trimethoxy silane and about 3 wt.% to 10wt.% of vinyl trimethoxy silane; mixture of 3wt.% of 5 wt.% of 3 glycidoxy propyl trimethoxy silane, 3wt.% of 5 wt.% of tri ethyl phosphate and 5wt.% of 8 wt.% of methyl trimethoxy silane; and mixture of 3wt.% of 5 wt.% of 3 glycidoxy propyl trimethoxy silane, 3wt.% of 5 wt.% of tri ethyl phosphate, 3wt.% of 5 wt.% of methyl trimethoxy silane and 3wt.% of 5 wt.% of vinyl trimethoxy silane.

9. The coating composition as claimed in claim 1, wherein the polypropylene dispersion of the Component-C is selected from a group comprising about 2 wt.% to 4 wt.% of micronized polypropylene wax dispersion, about 2 wt.% to 4 wt.% of Polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.

10. The coating composition as claimed in claim 1, wherein the polyethylene dispersion of the Component-C is selected from a group comprising about 0.4 wt.% to 0.7 wt.% of polyethylene wax dispersion, about 0.4 wt.% to 0.7 wt.% of Polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.

11. The coating composition as claimed in claim 1, wherein the acrylic polymer of the Component-C is selected from a group comprising about 0.4 wt.% to 0.7 wt.% of polyacrylate polymer , about 0.4 wt.% to 0.7 wt.% of silicone acrylate copolymer and a combination thereof.

12. The coating composition as claimed in claim 1, wherein the solvent of the Component-C is selected from a group comprising, about 35 wt.% to 55 wt.% of acidified demineralized water, about 25 wt.% to 35 wt.% of isopropyl alcohol, about 25 wt.% to 35 wt.% of ethyl alcohol and any combination thereof.

13. The coating composition as claimed in claim 1, wherein the additive is selected from a group comprising 0.4 wt.% to 0.8 wt.% of rust inhibitor, 2 wt.% to 4 wt.% of sol-gel based corrosion inhibitor, 2 wt.% to 4 wt.% of flexibilizer and any combination thereof; wherein the rust inhibitor is zinc salt of aromatic sulphonic acid, and the sol-gel based inhibitor is selected from a group comprising phosphate and silicon hydroxyl functional group, and the flexibilizer is selected from a group comprising iso-butylene glycol, texanol and propylene glycol; and wherein the ratio of rust inhibitor and sol-gel based corrosion inhibitor is about 1:5.

14. The coating composition as claimed in claim 1, wherein the Component-A is ranging from about 6 wt.% to 7wt.%, the Component-B is ranging from about 7wt.% to 9wt.% and the Component-C is ranging from about 84wt.% to 87wt%.

15. A method for preparing the coating composition as claimed claim 1 comprising mixing about 6 wt.% to 7wt.% of Component-A, about 7 wt.% to 9wt.% of Component-B and about 84 wt.% to 87wt.% of Component-C to obtain the coating composition.

16. The method as claimed in claim 15 comprising mixing the Component-A, the Component-B and the Component-C for a duration ranging from about 3 seconds to 5 seconds at a temperature ranging from about 500C to 600C.

17. The method as claimed in claim 15, wherein the Component-A is prepared by mixing the oxidizer dispersion, the surfactant dispersion and the solvent, at a predetermined temperature, for a predetermined duration.

18. The method as claimed in claim 15, wherein the Component-B is prepared by mixing the Component-A, the solvent and the surfactant at a predetermined temperature, for a predetermined duration.

19. The method as claimed in claim 15, wherein the Component-C is prepared by mixing the silane derivative, the polypropylene dispersion, the polyethylene dispersion, the acrylic polymer, the solvent and the additive at a predetermined temperature, for a predetermined duration.

20. A coated substrate comprising the coating composition as claimed in claim 1.

21. The coated substrate as claimed in claim 20, wherein the substrate is galvannealed steel/Galvanized iron/Aluminium/titanium/steel/stainless steel

22. A method of preparing the coated substrate as claimed in any one of claims 20 to 21, comprising roll coating, dipping orspraying the coating composition as claimed in claim 1 on to the substrate

23. The method as claimed in claim 22, further comprising passing the coated substrate through infrared oven at a temperature ranging from about 50ºC to 60ºC at about 80 MPM to 90 MPM speed, for a duration ranging from about 3 seconds to 5 seconds.

24. A method for reducing co-efficient of friction of a substrate comprising coating the composition as claimed in claim 1 on to the substrate according to the method as claimed in claim 22 to obtain the substrate with reduced co-efficient of friction.

25. The method as claimed in claim 24, wherein the co-efficient of friction of the substrate is reduced by about 19% to 27%.

26. A method for enhancing corrosion resistance or rust resistance of a substrate comprising coating the composition as claimed in claim 1 on to the substrate according to the method as claimed in claim 22 to obtain the substrate with enhanced corrosion resistance or rust resistance.
, Description:TECHNICAL FIELD
The present disclosure relates to a field of material science. The present disclosure particularly relates to a coating composition, a fast-drying coating composition for forming a protective coating. More particularly, the present disclosure relates to a protective coating composition that can be used to form a protective coating on a substrate such as iron, steel, stainless steel, galvannealed steel, aluminium, tin and titanium. The present disclosure further relates to a method for preparing the said coating composition. The present disclosure furthermore relates to a coated substrate comprising the said coating composition. The present disclosure also relates to use of said coating composition in lowering coefficient of friction and enhancing corrosion resistance and rust resistance of the coated substrate.

BACKGROUND OF THE DISCLOSURE
Some research work has done on an organic resin, a silane coupling agent and a two or more phenolic hydroxyl groups bonded to the benzene ring, wax component for good lubricity, corrosion resistance and scratch resistance and some has done work on high viscous fluoropolymer, especially 75-94 % PVDF, coating, 5-20 percent acrylic resin, and 1-15 % polyepoxide resin for excellent adhesion, on non-pre-treated (no primer) galvanized steel, providing fuel resistance and corrosion resistance.

In the recent practice, to reduce the powdering of metal substrates, particularly galvannealed steel, which is generally produced during press forming, automakers need to expel the produced powder after certain strokes of punch through press forming which attributes in loss of productivity and difficulty in ease of drawability of components.
In addition, there is a need to mitigate the problem of corrosion of materials such as fuel tank in motor vehicles, particularly in two-wheeler vehicles and contamination of fuel media due to the dissolution of zinc particles, which can chock the fuel injection pump.
Thus, there is a need for developing a protective composition which an improve the properties of the metal substrates which overcomes the problems mentioned above. The present disclosure overcomes the said problems and other related problem by developing a coating composition.

SUMMARY OF THE DISCLOSURE
An object of the present disclosure is to provide a coating composition which is inexpensive and an effective coating composition for providing improved formability, that significantly reduces coefficient of friction at both high temperature and room temperature and that enhances the corrosion resistance and rust resistance of a substrate.

The present disclosure accordingly provides for a coating composition comprising Component-A, Component-B and Component-C, which is inexpensive and provides for improved formability, significantly reduces coefficient of friction of a substrate coated with the said coating composition both at high temperature and at room temperature. The coating composition provides for enhanced corrosion resistance and enhanced rust resistance to the substrate coated with the said coating composition.
The present disclosure further relates to a method of preparing the said coating composition comprising mixing Component-A, Component-B and Component-C at a predetermined temperature for a predetermined duration.

The present disclosure further relates to a coated substrate comprising the said coating composition. The said coated substrate demonstrates reduced coefficient of friction at both high temperature and room temperature, demonstrates enhanced resistance to corrosion and rust.

The present disclosure further relates to method of preparing the coated substrate, comprising roll coating the said coating composition on to a substrate by film splitting technique.

The present disclosure further relates to a method of reducing co-efficient of friction of a substrate by coating the said composition by the said roll coating to obtain the coated substrate with reduced co-efficient of friction, wherein the co-efficient of friction of the coated substrate is reduced by about 19% to 29% when compared to uncoated substrate or a substrate coated with any other available coating composition.

The present disclosure further relates to a method of enhancing corrosion resistance or rust resistance of a substrate by coating the said composition by the said roll coating to obtain the coated substrate with enhanced resistance to corrosion or rust.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
For the purpose that the disclosure may be easily perceived and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying figures. The figures together with detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, in accordance with the present disclosure where:

FIGURE 1 illustrates a plot depicting the results of formability test for coated substrate of the present disclosure and uncoated substrate.

FIGURE 2 illustrates pictures of coated substrate of the present disclosure at 0hour, 500hours and 700hours upon subjecting the coated substrate to salt spray test.

FIGURE 3 illustrates pictures of immersion of coated substrate of the present disclosure and uncoated substrate in a fuel media.
FIGURE 4 illustrates comparison of coated substrate of the present disclosure and uncoated substrate for rust resistance after 105 days of immersion in foul fuel media.

FIGURE 5 illustrates pictures of coated substrate of the present disclosure after 10500 days of immersion in foul fuel media such as 80% petrol+20% aggressive ethanol, 40% petrol+60% aggressive ethanol, 60% petrol+40% aggressive ethanol and 100% ethanol, respectively.

FIGURE 6 illustrates pictures of seam welded coated substrate of the present disclosure after 105 days of immersion in foul media such as 20% ethanol, 40% ethanol, 60% ethanol and 100% ethanol, respectively.

DETAILED DESCRIPTION
The present disclosure relates to a coating composition.

In an embodiment of the present disclosure the coating composition is a fast-drying wax based waterborne dispersion.

In an embodiment of the present disclosure the coating composition comprises Component-A, Component-B and Component-C, wherein the Component-A comprises oxidizer dispersion, surfactant dispersion and solvent; the Component-B comprises the Component-A, solvent and surfactant dispersion; and the Component-C comprises silane derivative, polypropylene dispersion, polyethylene dispersion, acrylic polymer, solvent and additive.

In an embodiment of the present disclosure, the coating composition comprises about 6 wt.% to 7wt.% of the Component-A, about 7wt.% to 9wt.% of the Component-B and about 84 wt.% to 87wt.% of the Component-C.

In an embodiment of the present disclosure, the coating composition comprises about 6 wt.%, about 6.1 wt.%, about 6.2 wt.%, about 6.3 wt.%, about 6.4 wt.%, about 6.5 wt.%, about 6.6 wt.%, about 6.7 wt.%, about 6.8 wt.%, about 6.9 wt.% or about 7 wt.% of the Component-A

In an embodiment of the present disclosure, the coating composition comprises about 7 wt.%, about 7.1 wt.%, about 7.2 wt.%, about 7.3 wt.%, about 7.4 wt.%, about 7.5 wt.%, about 7.6 wt.%, about 7.7 wt.%, about 7.8 wt.%, about 7.9 wt.%, about 8 wt.%, about 8.1 wt.%, about 8.2 wt.%, about 8.3 wt.%, about 8.4 wt.%, about 8.5 wt.%, about 8.6 wt.%, about 8.7 wt.%, about 8.8 wt.%, about 8.9 wt.% or about 9 wt.% of the Component-B.

In an embodiment of the present disclosure, the coating composition comprises about 84wt.%, about 84.1 wt.%, about 84.2 wt.%, about 84.3 wt.%, about 84.4 wt.%, about 84.5 wt.%, about 84.6 wt.%, about 84.7 wt.%, about 84.8 wt.%, about 84.9 wt.%, about 85wt.%, about 85.1 wt.%, about 85.2 wt.%, about 85.3 wt.%, about 85.4 wt.%, about 85.5 wt.%, about 85.6 wt.%, about 85.7 wt.%, about 85.8 wt.%, about 85.9 wt.%, about 86 wt.%, about 86.1 wt.%, about 86.2 wt.%, about 86.3 wt.%, about 86.4 wt.%, about 86.5 wt.%, about 86.6 wt.%, about 86.7 wt.%, about 86.8 wt.%, about 86.9 wt.%, about 87 wt.% of the Component-C.

In an embodiment of the present disclosure, the oxidizer dispersion of the Component-A is selected from a group comprising mixture of digallic acid, butyl cellosolve, phosphoric acid, mixture of digallic acid, ethyl cellosolve and phosphoric acid, mixture of m-trigallic acid, butyl cellosolve, phosphoric acid and mixture of m-trigallic acid, ethyl cellosolve and phosphoric acid.

In an embodiment of the present disclosure, the oxidizer dispersion of the Component-A is selected from a group comprising mixture of about 3wt.% to 7wt.% of digallic acid, about 22wt.% to 28wt.% of butyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid; mixture of about 3wt.% to 7wt.% of digallic acid, about 22wt.% to 28wt.% of ethyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid; mixture of about 3wt.% to 7wt.% m-trigallic acid, about 22wt.% to 28wt.% of butyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid; and mixture of about 3wt.% to 7wt.% of m-trigallic acid, about 22wt.% to 28wt.% of ethyl cellosolve and about 30wt.% to 40wt.% of phosphoric acid.

In another embodiment of the present disclosure, the oxidizer dispersion of the component-A is selected from a group comprising:
mixture of about 3wt.%, about 3.5wt.%, about 4wt.%, about 4.5wt.%, about 5wt.%, about 5.5wt.%, about 6wt.%, about 6.5wt.% or about 7wt.% of digallic acid, about 22wt.%, about 22.5wt.%, about 23wt.%, about 23.5wt.%, about 24wt.%, about 24.5wt.%, about 25wt.%, about 25.5wt.%, about 26wt.%, about 26.5wt.%, about 27wt.%, about 27.5wt.% or about 28wt.% of butyl cellosolve and about 30wt.%, about 30.5wt.%, about 31wt.%, about 31.5wt.%, about 32wt.%, about 32.5wt.%, about 33wt.%, about 33.5wt.%, about 34wt.%, about 34.5wt.%, about 35wt.%, about 35.5wt.% or about 36wt.%, about 37wt.%, about 37.5wt.%, about 38wt.%, about 38.5wt.%, about 39wt.%, about 39.5wt.% or about 40wt.% of phosphoric acid;
mixture of about 3wt.%, about 3.5wt.%, about 4wt.%, about 4.5wt.%, about 5wt.%, about 5.5wt.%, about 6wt.%, about 6.5wt.% or about 7wt.% of digallic acid, about 22wt.%, about 22.5wt.%, about 23wt.%, about 23.5wt.%, about 24wt.%, about 24.5wt.%, about 25wt.%, about 25.5wt.%, about 26wt.%, about 26.5wt.%, about 27wt.%, about 27.5wt.% or about 28wt.% of ethyl cellosolve and about 30wt.%, about 30.5wt.%, about 31wt.%, about 31.5wt.%, about 32wt.%, about 32.5wt.%, about 33wt.%, about 33.5wt.%, about 34wt.%, about 34.5wt.%, about 35wt.%, about 35.5wt.% or about 36wt.%, about 37wt.%, about 37.5wt.%, about 38wt.%, about 38.5wt.%, about 39wt.%, about 39.5wt.% or about 40wt.% of phosphoric acid;
mixture of about 3wt.%, about 3.5wt.%, about 4wt.%, about 4.5wt.%, about 5wt.%, about 5.5wt.%, about 6wt.%, about 6.5wt.% or about 7wt.% of m-trigallic acid, about 22wt.%, about 22.5wt.%, about 23wt.%, about 23.5wt.%, about 24wt.%, about 24.5wt.%, about 25wt.%, about 25.5wt.%, about 26wt.%, about 26.5wt.%, about 27wt.%, about 27.5wt.% or about 28wt.% of butyl cellosolve and about 30wt.%, about 30.5wt.%, about 31wt.%, about 31.5wt.%, about 32wt.%, about 32.5wt.%, about 33wt.%, about 33.5wt.%, about 34wt.%, about 34.5wt.%, about 35wt.%, about 35.5wt.% or about 36wt.%, about 37wt.%, about 37.5wt.%, about 38wt.%, about 38.5wt.%, about 39wt.%, about 39.5wt.% or about 40wt.% of phosphoric acid; and
mixture of about 3wt.%, about 3.5wt.%, about 4wt.%, about 4.5wt.%, about 5wt.%, about 5.5wt.%, about 6wt.%, about 6.5wt.% or about 7wt.% of m-trigallic acid, about 22wt.%, about 22.5wt.%, about 23wt.%, about 23.5wt.%, about 24wt.%, about 24.5wt.%, about 25wt.%, about 25.5wt.%, about 26wt.%, about 26.5wt.%, about 27wt.%, about 27.5wt.% or about 28wt.% of ethyl cellosolve and about 30wt.%, about 30.5wt.%, about 31wt.%, about 31.5wt.%, about 32wt.%, about 32.5wt.%, about 33wt.%, about 33.5wt.%, about 34wt.%, about 34.5wt.%, about 35wt.%, about 35.5wt.% or about 36wt.%, about 37wt.%, about 37.5wt.%, about 38wt.%, about 38.5wt.%, about 39wt.%, about 39.5wt.% or about 40wt.% of phosphoric acid.

In an embodiment of the present disclosure, the surfactant dispersion of the Component-A is selected from a group comprising non-ionic fluorosurfactant, dialkyl sulphosuccinate, branched hydrocarbon surfactant and any combination thereof.
In an embodiment of the present disclosure, the surfactant dispersion of the Component-A is selected from a group comprising about 0.3wt.% to 0.5wt.% of non-ionic fluorosurfactant i.e capstone® FS-3100, about 0.3wt.% to 0.5wt.% of dialkyl sulphosuccinate, about 0.3wt.% to 0.5wt.% of branched hydrocarbon surfactant i.e DISPERBYK-2152.
In another embodiment of the present disclosure, the surfactant dispersion of the component-A is selected from a group comprising about 0.3wt.%, about 0.4wt.% or about 0.5wt.% of non-ionic fluorosurfactant, about about 0.3wt.%, about 0.4wt.% or about 0.5wt.% of dialkyl sulphosuccinate, about 0.3wt.%, about 0.4wt.% or about 0.5wt.% of branched hydrocarbon surfactant and any combination thereof.

In an embodiment of the present disclosure, the solvent of the Component-A is demineralized water.

In an embodiment of the present disclosure, the solvent of the Component-A is selected from a group comprising about 30wt.% to 40wt.% of demineralized water.

In another embodiment of the present disclosure, the solvent of the Component-A is selected from a group comprising about 30wt.%, about 31wt.%, about 32wt.%, about 33wt.%¸ about 34wt.%, about 35wt.%, about 36wt.%¸ about 37wt.%¸ about 38wt.%¸ about 39wt.%¸ or about 40wt.% of demineralized water.

In an embodiment of the present disclosure, the solvent of the component-B is selected from a group comprising iso-propyl alcohol, ethanol, mixture of isopropyl alcohol and ethanol and demineralized water.

In an embodiment of the present disclosure, the solvent of the Component-B is selected from a group comprising about 25wt.% to 35wt.% of iso-propyl alcohol, about 25wt.% to 35wt.% of ethanol, mixture of isopropyl alcohol and ethanol at a ratio of about 3:1 and about 15wt.% to 30wt.% of demineralized water.

In another embodiment of the present disclosure, the solvent of the Component-B is selected from a group comprising-
about 25wt.%, about 25.5wt.%, about 26wt.%, about 26.5wt.%¸ about 27wt.%, about 27.5wt.%, about 28wt.%, about 28.5wt.%, about 29wt.%, about 29.5wt.% or about 30wt.% of isopropyl alcohol,
about 25wt.%, about 25.5wt.%, about 26wt.%, about 26.5wt.%¸ about 27wt.%, about 27.5wt.%, about 28wt.%, about 28.5wt.%, about 29wt.%, about 29.5wt.% or about 30wt.% of ethanol,
mixture of isopropyl alcohol and ethanol at a ratio of about 1:1, about 2:1 or about 3:1, and about 15wt.%, about 16wt.%, about 17wt.%, about 18wt.%¸ about 19wt.%, about 20wt.%, about 21wt.%¸ about 22wt.%¸ about 23wt.%¸ about 24wt.%¸ about 25wt.%, about 26wt.%, about 27wt.%, about 28wt.%¸ about 29wt.% or about 30wt.% of demineralized water.

In an embodiment of the present disclosure, the surfactant dispersion of the Component-B is selected from a group comprising mixture of manganese phosphate, manganese sulphate, quaternary surfactant and phosphoric acid and mixture of manganese phosphate, manganese sulphate, nickel sulphate, quaternary ammonium surfactant and phosphoric acid.

In an embodiment of the present disclosure, the surfactant dispersion of the component-B is selected from group comprising mixture of about 3wt.% to 5wt.% of manganese phosphate, about 1.5wt.% to 2.5wt.% of manganese sulphate, about 0.03wt.% to 0.05wt.% of quaternary ammonium surfactant and about 10wt.% to 25wt.% of phosphoric acid; and mixture of about 3wt.% to 5wt.% manganese phosphate, about 1.5wt.% to 2.5wt.% of manganese sulphate, about 1.5wt.% to 2.5wt.% of nickel sulphate, about 0.03wt.% to 0.05wt.% of quaternary ammonium surfactant and about 10wt.% to 25wt.% of phosphoric acid.

In another embodiment of the present disclosure, the surfactant dispersion of the Component-B is selected from a group comprising-
mixture of about 3wt.%, about 3.5wt.%, about 4wt.% about 4.5wt.% or about 5wt.% of manganese phosphate, about 1.5wt.%, about 2wt.% or about 2.5wt.% of manganese sulphate, about 0.03wt.%, about 0.04wt.% or about 0.05wt.% of quaternary ammonium surfactant and about 10wt.%, about 15wt.%¸ about 20wt.%¸ or about 25wt.% of phosphoric acid.
mixture of about 3wt.%, about 3.5wt.%, about 4wt.% about 4.5wt.% or about 5wt.% of manganese phosphate, about 1.5wt.%, about 2wt.% or about 2.5wt.% of manganese sulphate, about 1.5wt.%, about 2wt.% or about 2.5wt.% of nickel sulphate, about 0.03wt.%, about 0.04wt.% or about 0.05wt.% of quaternary ammonium surfactant and about 10wt.%, about 15wt.%¸ about 20wt.%¸ or about 25wt.% of phosphoric acid, wherein the ratio of manganese sulphate and the nickel sulphate is about 1:1.

In an embodiment of the present disclosure, the Component-B comprises about 15wt.% to 20wt.% of Component-A.

In another embodiment of the present disclosure, the Component-B comprises about 15wt.%, about 15.5wt.%, about 16wt.%, about 16.5wt.%¸ about 17wt.%¸ about 17.5wt.%¸ about 18wt.%, about 18.5wt.%¸ about 19wt.%¸ about 19.5wt.% or about 20wt.%.

In an embodiment of the present disclosure, the silane derivative dispersion of the Component-C is selected from a group comprising mixture of 3-glycidoxy propyl trimethoxy silane and trimethoxy silane, mixture of 3-glycidoxy propyl trimethoxy silane, methyl trimethoxy silane and vinyl trimethoxy silane, mixture of 3-glycidoxy propyl trimethoxy silane, methyl trimethoxy silane, mixture of 3-glycidoxy propyl trimethoxy silane, trimethoxy silane and triethyl phosphate, mixture of methyl trimethoxy silane, vinyl trimethoxy silane, mixture of 3-glycidoxy propyl trimethoxy silane, triethyl phosphate and methyl trimethoxy silane and mixture of 3-glycidoxy propyl trimethoxy silane, propyl trimethoxy silane, triethyl phosphate, methyl trimethoxy silane and vinyl trimethoxy silane.

In an embodiment of the present disclosure, the silane derivative dispersion of the Component-C is selected from a group comprising-
mixture of 7wt.% to 10wt.% of 3- glycidoxy propyl trimethoxy silane and 7wt.% to 10wt.% of trimethoxy silane;
mixture of 7wt.% to 10wt.% of 3-glycidoxy propyl trimethoxy silane, 7wt.% to 10wt.% of methyl trimethoxy silane and 7wt.% to 10wt.% of vinyl trimethoxy silane;
mixture of 7wt.% to 10wt.% of 3- glycidoxy propyl trimethoxy silane and 7wt.% to 10wt.% of methyl trimethoxy silane;
mixture of 7wt.% to 10wt.% of 3- glycidoxy propyl trimethoxy silane and 7wt.% to 10wt.% of triethyl phosphate;
mixture of 3 wt.% to 10wt.% of methyl trimethoxy silane and 3 wt.% to 10wt.% of vinyl trimethoxy silane;
mixture of 3 wt. % 5 wt. % of 3 glycidoxy propyl trimethoxy silane, 3 wt. % of 5 wt. % of tri ethyl phosphate and 5wt. % to 8 wt. % of methyl trimethoxy silane; and
mixture of 3 wt. % to 5 wt. % of 3 glycidoxy propyl trimethoxy silane, 3 wt. % to 5 wt. % of tri ethyl phosphate, 3 wt. % to 5 wt. % of methyl trimethoxy silane and 3 wt. % to 5 wt. % of vinyl trimethoxy silane.

In another embodiment of the present disclosure, the silane derivative dispersion of the Component-C is selected from a group comprising:
mixture of about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of 3- glycidoxy propyl trimethoxy silane, about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of trimethoxy silane;
mixture of 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of 3- glycidoxy propyl trimethoxy silane, 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of methyl trimethoxy silane and 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of vinyl trimethoxy silane;
mixture of about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of 3- glycidoxy propyl trimethoxy silane, about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of methyl trimethoxy silane;
mixture of about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of 3- glycidoxy propyl trimethoxy silane, about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of triethyl phosphate;
mixture of about 3wt.%, about 3.5wt.%, about 4wt.%¸ about 4.5wt.%¸ about 5wt.%¸ about 5.5wt.% or about 6wt.%, about 6.5wt.%, about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of methyl trimethoxy silane and about 3wt.%, about 3.5wt.%, about 4wt.%¸ about 4.5wt.%¸ about 5wt.%¸ about 5.5wt.% or about 6wt.%, about 6.5wt.%, about 7wt.%, about 7.5wt.%, about 8wt.%¸ about 8.5wt.%¸ about 9wt.%¸ about 9.5wt.% or about 10wt.% of vinyl trimethoxy silane.
mixture of 3 wt. % to 5 wt. % of 3 glycidoxy propyl trimethoxy silane, 3 wt. % to 5 wt. % of tri ethyl phosphate and 5wt. % to 8 wt. % of methyl trimethoxy silane; and
mixture of 3 wt. % to 5 wt. % of 3 glycidoxy propyl trimethoxy silane, 3 wt. % to 5 wt. % of tri ethyl phosphate, 3 wt. % to 5 wt. % of methyl trimethoxy silane and 3 wt. % to 5 wt. % of vinyl trimethoxy silane.

In an embodiment of the present disclosure, the polypropylene dispersion of the Component-C is selected from a group comprising micronized polypropylene wax dispersion, polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.
In an embodiment of the present disclosure, the polypropylene dispersion of the Component-C is selected from a group comprising about 2 wt.% to 4 wt.% of micronized polypropylene wax dispersion, about 2 wt.% to 4 wt.% of Polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.

In another embodiment of the present disclosure, the polypropylene dispersion of the Component-C is selected from a group comprising about 2 wt.%, about 2.2 wt.%, about 2.4 wt.%, about 2.6 wt.%¸ about 2.8 wt.%, about 3 wt.%¸ about 3.2 wt.%¸ about 3.4 wt.%¸ about 3.6 wt.%¸ about 3.8 wt.% or about 4 wt.% of micronized polypropylene wax dispersion, about 2 wt.%, about 2.2 wt.%, about 2.4 wt.%, about 2.6 wt.%¸ about 2.8 wt.%, about 3 wt.%¸ about 3.2 wt.%¸ about 3.4 wt.%¸ about 3.6 wt.%¸ about 3.8 wt.% or about 4 wt.% of Polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.

In an embodiment of the present disclosure, the polyethylene dispersion of the Component-C is selected from a group comprising polyethylene wax dispersion, polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.

In an embodiment of the present disclosure, the polyethylene dispersion of the Component-C is selected from a group comprising about 0.4 wt.% to 0.7 wt.% of polyethylene wax dispersion, about 0.4 wt.% to 0.7 wt.% of Polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.

In another embodiment of the present disclosure, the polyethylene dispersion of the Component-C is selected from a group comprising about 0.4 wt.%, about 0.5 wt.%, about 0.6 wt.% or about 0.7 wt.% of polyethylene wax dispersion and about 0.4 wt.%, about 0.5 wt.%, about 0.6 wt.% or about 0.7 wt.% of Polytetrafluoroethylene (PTFE) modified polypropylene wax dispersion and a combination thereof.

In an embodiment of the present disclosure, the acrylic polymer of the Component-C is selected from a group comprising polyacrylate polymer, silicone acrylate copolymer and a combination thereof.

In an embodiment of the present disclosure, the acrylic polymer of the Component-C is selected from a group comprising about 0.4 wt.% to 0.7 wt.% of polyacrylate polymer i.e. BYK 3441, about 0.4 wt.% to 0.7 wt.% of silicone acrylate copolymer and a combination thereof.

In another embodiment of the present disclosure, the acrylic polymer of the Component-C is selected from a group comprising about 0.4 wt.%, about 0.5 wt.%, about 0.6 wt.% or about 0.7 wt.% of polyacrylate polymer, about 0.4 wt.%, about 0.5 wt.%, about 0.6 wt.% or about 0.7 wt.% of silicon acrylate copolymer and a combination thereof.

In an embodiment of the present disclosure, the solvent of the Component-C is selected from a group comprising demineralized water, acidified demineralized water, isopropyl alcohol, ethyl alcohol and any combination thereof.

In an embodiment of the present disclosure, the solvent of the Component-C is selected from a group comprising about 35 wt.% to 55 wt.% of acidified demineralized water, about 15 wt.% to 30 wt.% of isopropyl alcohol, about 10 wt.% to 35 wt.% of ethyl alcohol and any combination thereof.

In another embodiment of the present disclosure, the solvent of the Component-C is selected from a group comprising about 35 wt.%, about 40 wt.%, about 45 wt.%¸ about 50 wt.% or about 55 wt.% of acidified demineralized water, about 15 wt. %, about 20 wt. %, 25 wt.%, about 30 wt.% or about 35 wt.% of isopropyl alcohol, , about 10 wt.% , about 15 wt. %, about 20 wt. %, about 25 wt.%, about 30 wt.% or about 35 wt.% of ethyl alcohol and any combination thereof.

In an embodiment of the present disclosure, the additive is selected from a group comprising rush inhibitor, sol-gel based inhibitor, flexibilizer and any combination thereof.

In an embodiment of the present disclosure, the additive is selected from a group comprising about 0.4 wt.% to 0.8 wt.% of rust inhibitor, about 2 wt.% to 4 wt.% of sol-gel based corrosion inhibitor, about 2 wt.% to 4 wt.% of flexibilizer and any combination thereof.

In an embodiment of the present disclosure, the rust inhibitor is selected from a group comprising aromatic sulphonic acid i.e. zinc salt of aromatic sulphonic acid.

In an embodiment of the present disclosure, the sol-gel based inhibitor is selected from a group comprising phosphate, and silicone hydroxyl functional group.

In an embodiment of the present disclosure, the flexibilizer is selected from a group comprising iso-butylene glycol, texanol, propylene glycol.

In an embodiment of the present disclosure, the ratio of rust inhibitor and sol-gel based inhibitor is about 1:5.

In another embodiment of the present disclosure, the ratio of rust inhibitor and corrosion inhibitor is about 1:5.

In an embodiment of the present disclosure, the coating composition has a non-volatile content ranging from about 17% to 21%.

In another embodiment of the present disclosure, the coating composition has a non-volatile content of about 17%, about 17.5%, about 18%, about 18.5%, about 19%, about 19.5%, about 20%, about 20.5% or about 21%.

In an embodiment of the present disclosure, the non-volatile content of the Component-A of the coating composition is ranging from about 3% to 7%.

In another embodiment of the present disclosure, the non-volatile content of the Component-A of the coating composition is about 3%, about 3.5%, about 4%, about 4.5%, about 5%, about 5.5%, about 6%, about 6.5% or about 7%.

In an embodiment of the present disclosure, the non-volatile content of the Component-B of the coating composition is ranging from about 5% to 9%.

In another embodiment of the present disclosure, the non-volatile content of the Component-B of the coating composition is about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5% or about 9%.

In an embodiment of the present disclosure, the non-volatile content of the Component-C of the coating composition is ranging from about 5% to 9%.

In another embodiment of the present disclosure, the non-volatile content of the Component-C of the coating composition is about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5% or about 9%.

In an exemplary embodiment of the present disclosure, the coating composition comprises-
a) Component-A comprising digallic acid, butyl cellosolve, phosphoric acid, demineralized water and fluorinated wetting agent;
b) Component-B comprising isopropyl alcohol, demineralized water, quaternary ammonium surfactant, Component-A, phosphoric acid, manganese phosphate and manganese sulphate.
c) Component-C comprising mixture of 3 glycidoxy propyl trimethoxy silane, triethyl phosphate, metayl trimethoxy silane, mixture of zinc salt of sulphonic acid, sol-gel based inhibitor or adhesion promoter, micronized polypropylene wax dispersion, iso-butylene glycol, phosphoric acid, polyacrylate, iso-propyl alcohol, polyethylene dispersion, demineralized water.

In another exemplary embodiment of the present disclosure, the coating composition comprises-
a) Component-A comprising about 5wt.% of digallic acid, about 25wt.% of butyl cellosolve, about 35wt.% of phosphoric acid, about 34.5wt.% of demineralized water and about 0.5wt.% of fluorinated wetting agent;
b) Component-B comprising about 31.25wt.% of isopropyl alcohol, about 25wt.% of demineralized water, about 0.031wt.% of quaternary ammonium surfactant, about 18.75wt.% of Component-A, about 18.75wt.% of phosphoric acid, about 4.37wt.% of manganese phosphate and about 1.87wt.% of manganese sulphate; and
c) Component-C comprising mixture of about 3.5wt.% of 3 glycidoxy propyl trimethoxy silane, about 3.5wt.% of triethyl phosphate and about 5.7wt.% of metayl trimethoxy silane, mixture of about 0.6wt.% of zinc salt of sulphonic acid and about 2.92wt.% of sol-gel based inhibitor or adhesion promoter, about 2.45wt.% of micronized polypropylene wax dispersion, about 2.34wt.% of iso-butylene glycol, about 0.7wt.% of phosphoric acid, about 0.6wt.% of polyacrylate, about 30.17wt.% of iso-propyl alcohol, about 0.6wt.% of polyethylene wax dispersion and about 45.6wt.% of demineralized water.

In another exemplary an embodiment of the present disclosure, the coating composition comprises-
a) Component-A comprising m-trigallic acid, butyl cellosolve, phosphoric acid, demineralized water, di alkyl sulphosuccinate;
b) Component-B comprising ethyl alcohol, demineralized water, quaternary ammonium surfactant, Component-A, phosphoric acid, manganese phosphate and mixture of manganese sulphate and nickel sulphate; and
c) Component-C comprising mixture of 3 glycidoxy propyl trimethoxy silane, methyl trimethoxy silane and vinyl trimethoxy silane, mixture of zinc salt of sulphonic acid and solg-gel based inhibitor or adhesion promoter, PTFE modified polypropylene wax dispersion, iso-butylene glycol, phosphoric acid, silicone acrylate copolymer, iso-propyl alcohol, polyethylene wax dispersion and demineralized water.

In another exemplary an embodiment of the present disclosure, the coating composition comprises-
a) Component-A comprising about 7wt.% of m-trigallic acid, about 23wt.% of butyl cellosolve, about 35wt.% of phosphoric acid, about 34.7wt.% of demineralized water and about 0.3wt.% of di alkyl sulphosuccinate;
b) Component-B comprising about 34wt.% of ethyl alcohol, about 20wt.% of demineralized water, about 0.04wt.% of quaternary ammonium surfactant, about 18.75wt.% of Component-A, about 18wt.% of phosphoric acid, about 4.375wt.% of manganese phosphate and mixture of about 2.41wt.% of manganese sulphate and about 2.41wt.% of nickel sulphate; and
c) Component-C comprising mixture of about 8wt.% of 3 glycidoxy propyl trimethoxy silane, about 4wt.% of methyl trimethoxy silane and about 4wt.% of vinyl trimethoxy silane, mixture of about 0.6wt.% of zinc salt of sulphonic acid and about 2.92wt.% of sol-gel based inhibitor or adhesion promoter, about 2wt.% of PTFE modified polypropylene wax dispersion, about 2.34wt.% of iso-butylene glycol, about 0.7wt.% of phosphoric acid, about 0.6wt.% of silicone acrylate copolymer, about 30.17wt.% of iso-propyl alcohol, about 0.67wt.% of polyethylene wax dispersion and about 44wt.% of demineralized water.

In another exemplary an embodiment of the present disclosure, the coating composition comprises-
a) Component-A comprising m-trigallic acid, ethyl cellosolve, phosphoric acid, demineralized water and branched hydrocarbon surfactant;
b) Component-B comprising mixture of iso-propyl alcohol and ethyl alcohol, demineralized water, quaternary ammonium surfactant, quaternary ammonium surfactant, Component-A, manganese phosphate and manganese sulphate;
c) Component-C comprising mixture of 3 glycidoxy propyl trimethoxy silane, triethyl phosphate, methyl trimethoxy silane and vinyl trimethoxy silane, mixture of zinc salt of sulphonic acid and sol-gel based inhibitor or adhesion promoter, PTFE modified micronized polypropylene wax dispersion, iso-butylene glycol, phosphoric acid polyacrylate, ethyl alcohol, PTFE modified polyethylene wax dispersion and demineralized water.

In another exemplary an embodiment of the present disclosure, the coating composition comprises-
a) Component-A comprising about 5wt.% m-trigallic acid, about 28wt.% ethyl cellosolve, about 32wt.% phosphoric acid, about 34.6wt.% demineralized water and about 0.4wt.% branched hydrocarbon surfactant;
b) Component-B comprising mixture of about 21wt.% iso-propyl alcohol and about 7wt.% ethyl alcohol, about 31wt.% demineralized water, about 0.05wt.% quaternary ammonium surfactant, about 19.45wt.% Component-A, about 15wt.% phosphoric acid about 4.5wt.% manganese phosphate and about 2wt.% manganese sulphate;
c) Component-C comprising mixture of about 4wt.% 3 glycidoxy propyl trimethoxy silane, about 4wt.% triethyl phosphate, about 4wt.% methyl trimethoxy silane and about 4wt.% vinyl trimethoxy silane, mixture of about 0.6wt.% zinc salt of sulphonic acid and about 2.92wt.% sol-gel based inhibitor or adhesion promoter, about 3wt.%PTFE modified micronized polypropylene wax dispersion, about 2.48wt.%iso-butylene glycol, about 0.7wt.%phosphoric acid, about 0.6wt.% polyacrylate, about 32wt.%ethyl alcohol, about 0.7wt.% PTFE modified polyethylene wax dispersion and about 45wt.% demineralized water.

In an embodiment of the present disclosure, the coating composition upon application on to a substrate involves a drying time ranging from about 40 seconds to 46 seconds at a temperature ranging from about 20ºC to 40ºC, to obtain a coating thickness of about 0.7µ to 1µ.

In an embodiment of the present disclosure, the coating composition upon application on to a substrate involves a drying time ranging from about 40 seconds to 46 seconds at a temperature ranging from about 20ºC to 40ºC, to obtain a coating thickness of about 1.1µ to 1.5µ.

In an embodiment of the present disclosure, the coating composition upon application on a substrate involves a drying time of about 4-5 seconds at a temperature of about 50ºC to 600C, to obtain a coating thickness of about 0.7µ to 1µ.

In an embodiment of the present disclosure, the coating composition upon application on a substrate involves a drying time of about 6-7 seconds at a temperature of about 50ºC to 600C, to obtain a coating thickness of about 1.1µ to 1.5µ.

In an embodiment of the present disclosure, the coating composition reduces the coefficient of friction upon application on to a substrate in a range of about 23% to 27% at a temperature of about 65ºC.

In another embodiment of the present disclosure, the coating composition reduces the coefficient of friction upon application on a substrate by about 19% at room temperature.

The present disclosure further relates to a method of preparing the coating composition described above.

In an embodiment of the present disclosure, the method of preparing the coating composition comprises mixing Component-A, Component-B and Component-C at a predetermined temperature for a predetermined duration to obtain the coating composition.

In an embodiment of the present disclosure, the method of preparing the coating composition comprises mixing about 6 wt.% to 7wt.% of Component-A, about 7 wt.% to 9wt.% of Component-B and about 84 wt.% to 87wt.% of Component-C to obtain the coating composition.

In another embodiment of the present disclosure, the method of preparing the coating composition comprise mixing about 6 wt.%, about 6.1 wt.%, about 6.2 wt.%, about 6.3 wt.%, about 6.4 wt.%, about 6.5 wt.%, about 6.6 wt.%, about 6.7 wt.%, about 6.8 wt.%, about 6.9 wt.% or about 7 wt.% of the Component-A; about 7 wt.%, about 7.1 wt.%, about 7.2 wt.%, about 7.3 wt.%, about 7.4 wt.%, about 7.5 wt.%, about 7.6 wt.%, about 7.7 wt.%, about 7.8 wt.%, about 7.9 wt.%, about 8 wt.%, about 8.1 wt.%, about 8.2 wt.%, about 8.3 wt.%, about 8.4 wt.%, about 8.5 wt.%, about 8.6 wt.%, about 8.7 wt.%, about 8.8 wt.%, about 8.9 wt.% or about 9 wt.% of the Component-B; and about 84wt.%, about 84.1 wt.%, about 84.2 wt.%, about 84.3 wt.%, about 84.4 wt.%, about 84.5 wt.%, about 84.6 wt.%, about 84.7 wt.%, about 84.8 wt.%, about 84.9 wt.%, about 85wt.%, about 85.1 wt.%, about 85.2 wt.%, about 85.3 wt.%, about 85.4 wt.%, about 85.5 wt.%, about 85.6 wt.%, about 85.7 wt.%, about 85.8 wt.%, about 85.9 wt.%, about 86 wt.%, about 86.1 wt.%, about 86.2 wt.%, about 86.3 wt.%, about 86.4 wt.%, about 86.5 wt.%, about 86.6 wt.%, about 86.7 wt.%, about 86.8 wt.%, about 86.9 wt.%, about 87 wt.% of the Component-C for a duration of about 15 minutes to 30 minutes.

In an embodiment of the present disclosure, the method of preparing the coating comprises preparing the Component-A, the Component-B and Component-C, respectively and thereafter mixing the Component-A, the Component-B and the Component-C at a predetermined temperature for a predetermined duration.

In an embodiment of the present disclosure, the Component-A of the coating composition is prepared by mixing the oxidizer dispersion, the surfactant dispersion and the solvent at a predetermined temperature for a predetermined duration.

In an embodiment of the present disclosure, the Component-B of the coating composition is prepared by mixing the Component-A, the solvent and the surfactant dispersion at a predetermined temperature for a predetermined duration.

In an embodiment of the present disclosure, the Component-C of the coating composition is prepared by mixing the silane derivative, the polypropylene dispersion, the polyethylene dispersion, the acrylic polymer, the solvent and the additive.

In an embodiment of the present disclosure, the Component-A of the coating composition is prepared by mixing about 3wt.% to 7wt.% of digallic acid or m-trigallic acid, about 22wt.% to 28wt.% of butyl cellosolve or ethyl cellosolve, about 30wt.% to 40wt.% of phosphoric acid, with high shear stirring using mechanical stirrer up to about 1hour to obtain a mixture. To the mixture about 0.3wt.% to 0.5wt.% of non-ionic fluoro surfactant, dialkyl sulphosuccinate or branched hydrocarbon surfactant, followed by adding about 30wt.% to 40wt.% of demineralized water and then stirr the whole solution to obtain homogenous consistency of solution.

In an embodiment of the present disclosure, the Component-B of the of the coating composition is prepared by mixing about 15wt.% to 20wt.% of Component-A, about 10wt.% to 25wt.% phosphoric acid, about 15wt.% to 30wt.% of demineralized water and 25wt.% to 35wt.% of iso-propyl alcohol or ethanol in a reaction vessel on magnetic stirrer for about half an hour to obtain a mixture. To the mixture, about 3wt.% to 5wt.% of manganese phosphate, about 1.5wt.% to 2.5wt.% of manganese sulphate or mixture of about 1:1 manganese sulphate and nickel sulphate, about 0.003wt.% to 0.05wt.% of quaternary ammonium surfactant are added and stirred at high speed for about 2hours.

In an embodiment of the present disclosure, the manganese phosphate, nickel sulphate and manganese sulphate of the Component-B provides for corrosion resistance and reduces the co-efficient of friction both at high temperature and at room temperature.

In an embodiment of the present disclosure, the Component-C of the of the coating composition is prepared by mixing solution of about 7wt.% to 10wt.% of 3- glycidoxy propyl trimethoxy silane with trimethoxy silane at a ratio of about 1:1 or a solution of 7wt.% to 10wt.% 3- glycidoxy propyl trimethoxy silane and 7wt.% to 10wt.% of trimethoxy silane with vinyl trimethoxy silane or methyl trimethoxy silane in a ratio of about 1:1, at high speed using mechanical stirrer for half hour and then gradually about 35wt.% to 55wt.% of phosphorylated demineralized water is added in where about 0.6wt.% to 0.9wt.% of phosphoric acid is added into water to catalyse the reaction and preventing the precipitation while mixing into silane solution. Thereafter, about 25wt.% to 35wt.% of isopropyl alcohol or ethanol is added to decrease the drying time and viscosity of the solution and solution is mixed for about 1hour. To the solution, about 0.4wt.% to 0.8wt.% of zinc salt of aromatic sulphonic acid as rust inhibitor and about 2wt.% to 4wt.% of sol-gel based adhesion promotor/corrosion inhibitor in a ratio of about 1:5 is added and stirred for about 15 minutes at slow speed followed by mixing about 0.4wt.% to 0.7wt.% of polyacrylate or silicon acrylate copolymer based surface additive for levelling, about 4wt.% to 4wt.% of micronized polypropylene wax or PTFE modified polypropylene wax to provide abrasion resistance and 2wt.% to 4wt.% of iso butylene glycol for about 2hours using high speed mechanical stirrer. Thereafter, about 0.4wt.% to 0.7wt.% of polyethylene wax dispersion or PTFE modified polyethylene wax dispersion was added for achieving good lubricity. During the preparation, micronized polypropylene wax powder is first mixed with isopropyl alcohol to enhance the mixing of micronized polypropylene wax powder.

In an embodiment of the present disclosure, the di-gallic acid or m-trigalic acid of the Component-A of the coating composition provides very good corrosion inhibition. However, dissolution of the said di-gallic acid or m-trigallic acid during the preparation of the Component-A was possible due to the mixture of phosphoric acid and polar solvents like butyl cellosolve or ethyl cellosolve with water. The Component-A in the coating composition acts as a cleanser and corrosion inhibition on metal substrate for e.g. steel substrate.

In an embodiment of the present disclosure, the key element of the Component-B is the Component-A, manganese sulphate and nickel sulphate which can provide the lubricity as well as corrosion resistance. These properties can only be achieved by optimizing right amount of the surfactant, i.e. quaternary ammonium surfactant for dissolution of above elements into demineralized water and acid. The isopropyl alcohol, ethanol or a combination thereof employed in the Component-B aids in lowering the viscosity of the concentrated solution.

In an embodiment of the present disclosure, the silane derivative of the Component-C, such as 3-glycidoxy propyl trimethoxy silane, triethyl phosphate, vinyl trimethoxy silane are contributing the key role to get adherence and corrosion inhibition. In the said Component-C, the phosphorylated demineralized water reduces the viscosity by catalysing the said silane derivative. The isopropyl alcohol of the Component-C reduces the viscosity and the surface cracking of the coating composition is prevented by iso-butylene glycol of the coating composition. Further, the micronized polypropylene/PTFE modified polypropylene wax dispersion with polyethylene/PTFE modified polyethylene wax dispersion of the Component-C increases the lubricity of the coating composition.

The present disclosure further relates to a coated substrate comprising the coating composition described above.

In an embodiment of the present disclosure, the substrate is selected from a group comprising to iron, steel, stainless steel, galvannealed steel, aluminium, tin and titanium.

In an embodiment of the present disclosure, the coated substrate comprises the coating composition at a thickness ranging from about 0.5µ to 1.5µ.

In an embodiment of the present disclosure, the coated substrate comprises the coating composition at a thickness of about 0.5µ, about 0.6µ, about 0.7µ, about 0.8µ, about 0.9µ, about 1.0µ, about 1.1µ, about 1.2µ, about 1.3µ, about 1.4µ or about 1.5µ.

In an embodiment of the present disclosure, the coated substrate has reduced co-efficient of friction ranging from about 19% to 27% when compared to an uncoated substrate.

In another embodiment of the present disclosure, the coated substrate has reduced co-efficient of friction of about 19%, about 20%, about 21%¸ about 22%¸ about 23%¸ about 24%¸ about 25%¸ about 26% or about 27% when compared to an uncoated substrate.

In an embodiment of the present disclosure, the coated substrate is resistant to corrosion.

In an embodiment of the present disclosure, the coated substrate is resistant to rust.

The present disclosure further relates to a method of preparing the coated substrate described above.

In an embodiment of the present disclosure, the method of preparing a coated substrate comprises single step roll coating of the coating composition on to a substrate, wherein layer of the coating composition from the surface of roller is transferred to surface of the substrate to obtain coated substrate.

In an embodiment of the present disclosure, the coated substrate is passed through infrared oven at a temperature ranging from about 50ºC to 60ºC at about 80 MPM to 90 MPM speed, for a duration ranging from about 3 to 5 sec.

In another embodiment of the present disclosure, the coated substrate is passed through infrared oven at a temperature of about 50ºC, about 52ºC, about 54ºC, about 56ºC, about 58ºC or about 60ºC at about 80 MPM, about 82 MPM, about 84 MPM, about 86 MPM, about 88 MPM, about to 90 MPM speed, for a duration ranging from about 3 seconds to 5 seconds.

In an embodiment of the present disclosure, the roller employed for preparing the coated substrate is neoprene coated roller comprising pick up roll and applicator roll at bottom side and upper side.

The present disclosure further relates to use of the coating composition for reducing co-efficient of friction in a substrate by coating the substrate with the said coating composition, wherein the said coating composition is applied on to the substrate by techniques, such as roll coating, spraying and dipping.

The present disclosure furthermore relates to use of the coating composition for enhancing corrosion resistance of a substrate by coating the substrate with the said coating composition, wherein the said coating composition is applied on to the substrate by techniques, such as roll coating, spraying and dipping.

The present disclosure furthermore relates to use of the coating composition for enhancing rust resistance of a substrate by coating the substrate with the said coating composition, wherein the said coating composition is applied on to the substrate by techniques, such as roll coating, spraying and dipping.

Additional embodiments and features of the present disclosure will be apparent to one of ordinary skill in art based upon the description provided. The embodiments provide various features and advantageous details thereof in the description. Description of well-known/conventional methods and techniques are omitted so as to not unnecessarily obscure the embodiments. The examples provided herein are intended merely to facilitate an understanding of ways in which the embodiments provided may be practiced and to further enable those of skilled in the art to practice the embodiments provided. Accordingly, the following examples should not be construed as limiting the scope of the embodiments.

EXAMPLES

EXAMPLE 1: Preparation of the Coating Composition
Preparation of Component-A
About 5 wt.% of digallic acid was added to about 25wt.% of butyl cellosolve and 35 wt.% of phosphoric acid, followed by mixing with high shear mixing using mechanical stirrer for about 1hour. The butyl cellosolve and phosphoric acid dissolves the digallic acid. To the solution about 0.5wt.% of non-ionic fluoro-surfactant as flow and levelling agent was added, followed by adding 34.5 wt.% of demineralized water to lower the viscosity and mixed until a homogenous solution is obtained.

Preparation of Component-B
A solution of about 18.75 wt.% of Component-A with about 18.75 wt.% of phosphoric acid, about 25 wt.% of demineralized water and about 31.25 wt.% of iso-propyl alcohol were added together in a reaction vessel on magnetic stirrer in a container and mixed for about half an hour and then about 4.375 wt. % of manganese phosphate and about 1.875 wt. % of manganese sulphate with about 0.031 % of quaternary ammonium surfactant were added and stirred at high speed for about 2 hours. During the preparation, manganese phosphate can only be dissolved by using phosphoric acid and Component-A, otherwise it cannot be dissolved. Further, the dissolution of manganese sulphate requires the Component-A, the phosphoric acid, manganese and the cationic surfactant.

Preparation of Component-C
A solution of about 3.5 wt.% of 3-glycidoxy propyl trimethoxy silane, about 3.5 wt. % of triethyl phosphate and about 7wt.% of methyl trimethoxy silane were mixed at higher speed using mechanical stirrer for about half an hour then gradually about 46.3 wt. % of phosphorylated demineralized water was added, wherein about 0.7 wt. % of phosphoric acid was added into water to catalyze the reaction and preventing the precipitation while mixing into silane solution. Then, about 30.17 wt. % of isopropyl alcohol was added to decrease the drying time and viscosity of the solution, followed by mixing the solution for about 1 hour. Further, a solution of about 0.6 wt. % of zinc salt of an aromatic sulphonic acid as rust inhibitor and about 2.92 wt. % of sol-gel based adhesion promotor/corrosion inhibitor in a ratio of about 1:5 was added and stirred for about 15 minutes at slow speed followed by adding about 0.6 wt. % of polyacrylate based levelling agent, about 2.45 wt. % of micronized polypropylene wax to provide abrasion resistance and about 2.34 wt.% of iso-butylene glycol and mixed for about 2 hours using high speed mechanical stirrer. Finally, about 0.6 wt. % of polyethylene wax dispersion is added for enhancement in lubricity and mixed to obtain a homogenous solution.

About 6.5 wt. % of Component-A, about 8 wt. % of Component-A and about 85.5 wt. % of Component-A was mixed in a container for about 15 minutes using stirrer to obtain the coating composition in a form of a solution. The obtained coating composition is a stable solution without any settling.

Component-A Component-B Component-C
Ingredients Wt.% Ingredients Wt. % Ingredients Wt. %
Di gallic acid 5 Iso-propyl alcohol 31.25 3 glycidoxy propyl trimethoxy silane: Tri ethyl phosphate: Methyl trimethoxy silane 3.5:3.5:7
Butyl Cellosolve 25 DM water 25 Zinc salt of sulphonic acid: sol-gel based inhibitor/adhesion promotor 0.6:2.92

Phosphoric acid 35 Quaternary ammonium surfactant
0.03125 Micronized polypropylene wax dispersion 2.45
DM water 34.5 Part A 18.75 Iso-butylene glycol 2.34
Fluorinated wetting agent 0.5
H3PO4 18.75 Phosphoric Acid 0.7
Manganese phosphate 4.375 Polyacrylate based surface additive 0.6
Manganese sulphate 1.875 Iso-propyl alcohol 30.17
Polyethylene wax dispersion 0.6
DM water 45.6

Table 1: Coating composition according to Example 1

EXAMPLE 2: Preparation of the Coating Composition
Preparation of Component-A
About 7 wt.% of m-trigallic acid was added to about 23wt.% of butyl cellosolve and 35 wt.% of phosphoric acid, followed by mixing with high shear mixing using mechanical stirrer for about 1hour. The butyl cellosolve and phosphoric acid dissolves the m-trigallic acid. To the solution about 0.3wt.% of dialkyl sulphosuccinate as flow and levelling agent was added, followed by adding 34.7 wt.% of demineralized water to lower the viscosity and mixed until a homogenous solution is obtained.

Preparation of Component-B
A solution of about 18.75 wt.% of Component-A with about 18 wt.% of phosphoric acid, about 20 wt.% of demineralized water and about 34 wt.% of ethyl alcohol were added together in a reaction vessel on magnetic stirrer in a container and mixed for about half an hour and then about 4.375 wt. % of manganese phosphate and about 2.41wt. % of manganese sulphate and 2.41 wt.% of nickel sulphate with about 0.031 % of quaternary ammonium surfactant were added and stirred at high speed for about 2 hours. During the preparation, manganese phosphate can only be dissolved by using phosphoric acid and Component-A, otherwise it cannot be dissolved. Further, the dissolution of manganese sulphate requires the Component-A, the phosphoric acid, manganese and the cationic surfactant.

Preparation of Component-C
A solution of about 8 wt.% of 3-glycidoxy propyl trimethoxy silane, about 4wt. % of methyl trimethoxy silane and about 4wt.% of vinyl trimethoxy silane were mixed at higher speed using mechanical stirrer for about half an hour then gradually about 44 wt. % of phosphorylated demineralized water was added, wherein about 0.7 wt. % of phosphoric acid was added into water to catalyze the reaction and preventing the precipitation while mixing into silane solution. Then, about 30.17 wt. % of isopropyl alcohol was added to decrease the drying time and viscosity of the solution, followed by mixing the solution for about 1 hour. Further, a solution of about 0.6 wt. % of zinc salt of an aromatic sulphonic acid as rust inhibitor and about 2.92 wt. % of sol-gel based adhesion promotor/corrosion inhibitor in a ratio of about 1:5 was added and stirred for about 15 minutes at slow speed followed by adding about 0.6 wt. % of silicon acrylate copolymer based levelling agent, about 2 wt. % of PTFE modified polypropylene wax to provide abrasion resistance and about 2.34 wt.% of iso-butylene glycol and mixed for about 2 hours using high speed mechanical stirrer. Finally, about 0.67 wt. % of polyethylene wax dispersion was added for enhancement in lubricity and mixed to obtain a homogenous solution.

About 6 wt. % of Component-A, about 9 wt. % of Component-A and about 85 wt. % of Component-A was mixed in a container for about 15 minutes using stirrer to obtain the coating composition in a form of a solution. The obtained coating composition was a stable solution without any settling.

EXAMPLE 3: Preparation of the Coating Composition
Preparation of Component-A
About 5 wt.% of m-trigallic acid was added to about 28wt.% of butyl cellosolve and 35 wt.% of phosphoric acid, followed by mixing with high shear mixing using mechanical stirrer for about 1hour. The butyl cellosolve and phosphoric acid dissolves the m-trigallic acid. To the solution about 0.4wt.% of branched hydrocarbon surfactant as flow and levelling agent was added, followed by adding 34.6 wt.% of demineralized water to lower the viscosity and mixed until a homogenous solution is obtained.

Preparation of Component-B
A solution of about 19.45 wt.% of Component-A with about 15 wt.% of phosphoric acid, about 31wt.% of demineralized water and about 21 wt.% of iso-propyl alcohol and 7wt.% of ethyl alcohol were added together in a reaction vessel on magnetic stirrer in a container and mixed for about half an hour and then about 4.5 wt. % of manganese phosphate and about 2wt. % of manganese sulphate with about 0.05 % of quaternary ammonium surfactant were added and stirred at high speed for about 2 hours. During the preparation, manganese phosphate can only be dissolved by using phosphoric acid and Component-A, otherwise it cannot be dissolved. Further, the dissolution of manganese sulphate requires Component-A, phosphoric acid, manganese and cationic surfactant.

Preparation of Component-C
A solution of about 4 wt.% of 3-glycidoxy propyl trimethoxy silane, about 4wt. % of methyl trimethoxy silane, about 4wt.% of triethyl phosphate and about 4wt.% of vinyl trimethoxy silane were mixed at higher speed using mechanical stirrer for about half an hour then gradually about 46.3 wt. % of phosphorylated demineralized water is added, wherein about 0.7 wt. % of phosphoric acid was added into water to catalyze the reaction and preventing the precipitation while mixing into silane solution. Then, about 32 wt. % of ethyl alcohol was added to decrease the drying time and viscosity of the solution, followed by mixing the solution for about 1 hour. Further, a solution of about 0.6 wt. % of zinc salt of an aromatic sulphonic acid as rust inhibitor and about 2.92 wt. % of sol-gel based adhesion promotor/corrosion inhibitor in a ratio of about 1:5 was added and stirred for about 15 minutes at slow speed followed by adding about 0.6 wt. % of polyacrylate based levelling agent, about 3 wt. % of PTFE modified polypropylene wax to provide abrasion resistance and about 2.48 wt.% of iso-butylene glycol and mixed for about 2 hours using high speed mechanical stirrer. Finally, about 0.7 wt. % of polyethylene wax dispersion is added for enhancement in lubricity and mixed to obtain a homogenous solution.

About 6.5 wt. % of Component-A, about 7 wt. % of Component-A and about 86.5 wt. % of Component-A was mixed in a container for about 15 minutes using stirrer to obtain the coating composition in a form of a solution. The obtained coating composition was a stable solution without any settling.

EXAMPLE 4: Preparation of the Coated Substrate
Galvannealed steel (GA steel) was passed through neoprene coated roller. The roller comprises two rolls, one is the pickup roll and second is the applicator roll at bottom side and upper side. The strip of galvannealed steel (substrate) upon passing through the roller was coated with the composition through film splitting technique at both side of the strip by controlling the wet thickness of the composition, followed by passing the coated strip (coated substrate) through infrared oven maintained at a temperature ranging from about 50ºC to 60ºC at about 80MPM to 90MPM speed.

EXAMPLE 5: Experiments assessing the improved properties of the coated substrate, such as improved formability, reduced co-efficient of friction, improved corrosion and rust resistance.
A. Assessment of improved formability of the coated substrate
To Examine the improvement in formability, tests were conducted using punching operation on a 70 T double action forming press. The punching operation was done using two different punch diameters, about 50mm and about 70mm.
Procedure: It is a flat sheet metal forming process. The sheet metal blank is radially drawn into a forming die by the mechanical action of a punch which results the shape transformation with material retention of blank into cup. When blank/sheet metal is drawn easily in lower punch force then it is indicating good formability.
The results (illustrated in Figure 1) clearly indicate remarkable improvement in formability of coated GA steel.
At each blank holding force, the lower punch force indicating the lower friction and improved formability of the coated GA steel during press forming process as evident by Fig.1
The coating composition on the substrate (GA steel) alters the surface of the GA component during press forming which lowers the required drawing force and at the same time reduces the powdering which in turn improves the productivity.

B. Assessment of reduced/lower coefficient of friction of the coated substrate
The tests were conducted at 2KN load using 50KN servo-electric biaxial machine at three different speeds i.e. 100mm/min, 200mm/min and 400mm/min.

Procedure and observation: Average pull load is measured and friction factor is calculated using the equation-1. Denominator is multiplied by 2 because two surfaces of the sample are resisting the pull load. Normal load & pull distance is varied depending upon the requirement of the customer. Pull speed is usually maintained at 100mm/min unless specified by customer.
???????????????? ????????????=???????? ????????2×???????????? ???????? - (1)

Coated substrate (coated GA steel) demonstrated lower coefficient of friction (COF) when compared to uncoated GA steel at all the said three speeds.
The coated GA steel demonstrated about 23% to 27% lower coefficient of friction at a temperature of about 65ºC at the speeds of 100mm/min, 200mm/min and 400mm/min, respectively, illustrated in Table 2. Further, the coated GA steel demonstrated about 19% lower coefficient of friction at room temperature at a speed of about 100mm/min.

Temperature Speed (mm/min) Avg.COF of uncoated substrate Avg. COF of coated substrate % lowering of COF in coated substrate
65ºC 100 0.157 0.120 24%
200 0.152 0.117 23%
400 0.143 0.104 27%
Room temperature 100 0.183 0.148 19%

Table 2: Measurement of coefficient of friction at 2KN load.

C. Assessment of improved resistance of the coated substrate to corrosion and rust
Salt Spray test (ASTM B117)
The coated substrate (coated GA steel) was exposed to salt spray in salt spray fog chamber in accordance with ASTM B117.
Procedure: Non-oiled flat coated samples (8*4 inch) were cut via automated cutter carefully without surface contamination. Sealing the edges either by adhesive tape or lacquering followed by adhesive tape to avoid the rusting of the edges. placing the prepared samples in Fog Chamber in the trays (which is having a proper angle of 450 as per the standard) with proper marking of direction and naming at back side.
Observation: Fog chamber is turned off for about 10minutes to 15 minutes before taking out the sample for assessment which is generally done at each 24 hours of intervals. Sample is rinsed with DM water and allowed it for either room temperature drying or forced drying. Then, the samples were assessed at front side. There was no formation of white rust on the coated substrate until about 500hours. And there was no formation of red rust even after about 700hours.
Figure 2 illustrates the coated GA steel after exposure to salt spray fog chamber at 0hours, 500hours and 700hours. The figure depicts no formation of white rust and/or red rust at about 500hours and about 700hours, respectively.

Foul Fuel Test (CE 10A)
Dome shaped (having about 25% to 30% elongation) coated GA steel (coated substrate) was immersed in foul fuel media for about 105 days. The foul fuel media comprises about 15 vol % to 85vol% of petrol and 15vol% to 85vol% of ethanol, the aggressiveness of the ethanol in the said foul fuel media is due to a solution which contains about 816g (1.034L) of denatured ethanol, about 8.103 g(8.1ml) of demineralized water, about 0.004g of sodium chloride, about 0.021g(11µl) of sulphuric acid, 0.061g(58µl) of glacial acetic acid. Figure 3 illustrates the immersion of the coated substrate and uncoated substrate in the said foul fuel media.
There was no formation of rust and no particle contamination was observed on the coated substrate even after 105 days of immersion in the foul fuel media, however, white rust was formed on the uncoated substrate (illustrated in figure 4).

In the same manner, the dome shaped coated GA steel (coated substrate) and seam welded GA steel was immersed in foul fuel media having 20%, 40%, 60% and 100% ethanol, respectively. The dome shaped coated GA showed no formation of rust even after 105days of immersion in the said foul fuel media having different concentrations of ethanol (illustrated in figure 5).

The seam welded GA steel showed no formation of rust even after 105 days of immersion in the said foul fuel media having different concentrations of ethanol (illustrated in figure 6).