FIELD OF INVENTION:
The present invention relates to a waterborne coating solution more particularly to an
ecofriendly hybrid silane-phosphorous containing polyphenol coating solution that can
improve corrosion, weldability, fuel resistance and formability properties on galva
annealed (GA) substrates.
BACKGROUND AND PRIOR ART OF INVENTION;
Metallic-coated steel sheet is being used, particularly in industrial metal buildings,
steel framing members for both commercial (automatic fuel tank) and residential
structures, and the extended corrosion warranties of automobiles such as zinc
(galvanized iron) and zinc -iron alloy (galvanneal iron ) metal coating on steel surfaces
but all have some limitations for providing good formability (reduction in powdering
during forming), spot weldability, and fuel resistively in fuel tank with an excellent
corrosion resistance.
EP Patent Number 1705231 discloses a non-chromate aqueous metal surface treating
composition comprises water; and organosilicon compound obtained through
hydrolysis of 100 pbw of hydrolysable silane bearing a nitrogen/ containing organic
group, and 5/200 pbw of a different hydrolysable silane such as
RlnR33/nSi/(CH2)a/SiRlnR33/n (2) or its partial hydrolyzate. Rl=nitrogen/free,
optinally substituted, monovalent 1/8C hydrocarbon; R2, R3=1/4C alkoxy or acyloxy
group; Y=nitrogen/containing organic group; m=0 or l;a=l/10.
US Patent Number 6432191 B2 discloses a silane based coating composition provide
durable, corrosion resistant coatings on metal and non-metal surfaces. A typical
composition may include one or a mixture or silanes, such as methyltrimethoxysilane
and phenyltrimethoxysilane. The coating compositions may be formulated with either
acidic or basic catalysts, the latter being especially suitable for coating steel
substrates. Primer coating compositions which include two or more polyfunctional

organosilanes but no monofunctional organosilanes provide strongly adherent
corrosion resistant primer coatings for metals and are very adherent to polyurethane,
epoxy and oter resin topcoats.
US Patent number 4,11,3665 discloses the chemically resistant ambient curable
coatings based on a binder of which the major portion is prepared by reacting, in an
acidic solution, trialkoxysilanes (e.g., methyltriethoxysilane) with aliphatic polyols,
silicones or both, Barium fillers, such as beriummetaborate , may be added to provide
resistance to sulfur dioxide. Zinc oxide or metallic Zinc may be included for further
corrosion resistance. The compositions may be applied to, e.g., steel petroleum tanks,
by spraying, concrete, vitreous surfaces.
US Patent number 4113665 discloses the binders for preparing coatings resistant to
attact by solvents, chemicals; heat and weathering have as the major portion of the
binders, a binder prepared by reacting, in the presence of an acidic solution: a)
trialkoxysilanes having the formula 1

where Ri is selected from the group consisting of aryl, alkyl, and cycloalkyl groups
containing p to about 6 carbon atoms and where each R2 is independently selected
from the group consisting of alkyl, hydroxyalkyl, alkoxyalkyl and hydroxyalkoxyalkyl
groups containing up to about 6 carbon atoms, with: (b) (i) aliphatic 'polyols
containing an average of at least two carbon bonded hydroxyl groups per polyol and
having an average molecular weight of at least 62 and /or (ii) silicon intermediates of
the formula 2. Where each R3 is independently selected from the group consisting 'of
the hydroxy group amd alkyl, aryl and alkoxy groups having up to '6 carbon atoms,

where each R4 is independently selected from the group consisting of hydrogen and
alkyl and aryl groups having us to about 6 carbon atoms.
US Patent Number 5066698 discloses a high solids coating composition useful as a
clear coat for an automotive clear coat/color coat finish which contains about 40-80%
by weight of a binder and correspondingly about 20-60% by of a liquid organic carrier;
wherein the binder contains about; a) An acrylic solution polymer of polymerized
monomers of ethylenically unsaturated esters of acrylic acid or methacrylic acid and a
hydroxyl no of about 4000-2000 b) A dispersed polymer or polymerized monomers
having stabilizer resin segment that is relatively insoluble in the organic carrier, c) A
silioxane oligomer having -OH and -OR groups attached to the silane atoms of the
oligomer where R is an alkyl group having 1-6 carbon atoms in the alkyl group or an
aryl group and the oligomer has a weight average molecular weight of about 500-5000.
d) An alkylated melamine formaldehyde resin.
US Patent number 6329488 Bl discloses the invention is drawn to silane copolymers
prepared from the reaction of one or more polyisocyanates with one or more lubricious
polymers having at least two functional groups, which may be the same or different,
that are reactive with an isocyanate functional group and with one or more organo-
functional silanes having at least two functional groups, which may be the same or
different, that ate reactive with an isocyanate functional group and at least one
functional group reactive with a silicon rubber substrate. The silane copolymer
coatings of the invention are elastic, lubricious, and resist wet abrasion. Although the
preferred substrate is a polysiloxane rubber, but this copolymer is also useful for
coating other difficult to coat substrates, such as polyethylene and polypropylene, as
well as other polymers, glass, metal and ceramics.
US Patent number 5,879,437 describes a coating composition containing a tetra-alkyl
silicate or monomeric or oligomeric hydrolysis product thereof, present in a proportion
of 40-90% by weight based on the non-volatile content of the composition and a
hydrous oxide sol (Type A or Type B), in an amount such that the oxide constitutes
10-60% by weight of the non-volatiles. According to the patentees, this coating

composition is suitable for the pretreatment of solid surfaces such as metals generally,
including steel, titanium, copper, Zinc and, particularly aluminum, it improve
adhesion properties of the pretreated surface to subsequently applied coatings, such
as paint, varnish, lacquer; or of adhesive, either in the presence or absence of a
lubricant.
In recent years, there are several ecofriendly, Cr+6 and lead free anticorrosive coatings
have been developed based on organic, inorganic and hybrid coatings. These coatings
absorb on the surface of the galvanized and galvannealed iron surfaces. Some coatings
include an aluminum coating, a 55% aluminum-zinc, and a zinc-5% aluminum alloy
coating. These latter products can offer enhanced corrosion resistance in atmospheric
exposure and other applications.
The present invention relates to synthesis of a waterborne eco-friendly reactive coating
composition for metallic surface such as galvannealed iron. In addition of hybrid
organic-inorganic silane based binder, the compositions of the present invention have
been modified by phosphorous containing polyphenol structure which is responsible
for the conversion of absorption coating into reactive coating by bonding with surface
of the GA substrate. This chemistry helps into improving all the required properties
such as corrosion resistance, reducing powdering during forming, fuel and solvent
resistance with excellent adhesion properties.
Hence, the invention is usable in fuel tank of automotive, primer for temporary
protection, providing good adherence to the epoxy/ polyurethane top coat, usable in
the welding zone due to no extra sparking of coatings and can be usable to mitigate
the problem of powdering during forming by providing high lubricity and less friction
of coefficient as compare to the uncoated galvannealed sheet.
OBJECTS OF THE INVENTION;
It is therefore, an object of the present invention to propose an eco-friendly hybrid
silane-phosphorous containing polyphenol coatings that improve corrosion,
weldability, fuel resistance and formability properties on galva annealed substrates.

Another objection of the present invention is to propose synthesis of a waterborne
coating solution that can be used in fuel tank of automotive primer for temporary
protection providing good adherence to the epoxy/ polyurethane top coat.
Another object of the present invention is to propose synthesis of waterborne coating
solution usable in the welding zone due to no extra sparking of coatings.
Another object of the present invention is to propose synthesis of waterborne coating
solution that can be used to mitigate the problem of powdering during forming by
providing high lubricity and less friction of lubricity and less friction of coefficient as
compare to the uncoated galvannealed sheet.
SUMMARY OF THE INVENTION;
According to this invention, there is provided a waterborne coating solution
comprising:
a silane-based resin (10-15 wt. %);
an aqueous solution of phosphorous containing polyphenol (3-10 wt. %);
a acrylic silicon based leveling agent (0.2-0.3 wt.%);
a lower alkyl alcohol based flowing and flexibilizer agent (2.5 wt.%); metal salt
based barium sulphonates flash rust inhibitors (1-5.5 wt.%); and
polar solvents (20-30 wt.%).
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:
Fig 1 shows Fourier Transform-Infrared spectroscopy of base solution.
Fig 2 shows salt spray tests of coated GA substrates (Example 1, 2 and 3) and
uncoated GA sheet before forming.
(a) SST of Coated GA substrates- Example 1

(b) SST of Coated GA substrates- Example 2
(c) SST of Coated GA substrates- Example 3
(d) SST of Coated GA substrates- Uncoated GA substrates
Fig 3 shows salt spray tests of coated GA substrates (Example 1, 2 and 3) and
uncoated GA sheet after forming.
(a) SST after forming test: Example 1
(b) SST after forming test: Example 2
(c) SST after forming test: Example 3
(d) SST after forming test: Uncoated GA
Fig 4 shows solvent and fuel resistance testing solution and tested coated GA samples
(Example 1, 2 and 3) and uncoated GA sample after 1500 hours.
Fig 5 shows cupping test of coated GA samples and uncoated GA sheet.
DETAILED DESCRIPTION OF THE INVENTION;
The invention, provides a method for producing eco-friendly coatings on steel
substrate (mainly for galva annealed substrate).
More particularly the present invention provides a waterborne coating solution
comprising about 10-15 wt.% of silane based resin, about 3-10 wt. % of aqueous
solution of phosphorous containing polyphenol, about 0.2-0.3 wt.% acrylic silicon
based leveling agents, about 2-5 wt.% of lower alkyl alcohol based flowing and
flexibilixer agent, about 1-5.5 wt.% of metal salt based barium sulphonates flash rust
inhibitors and about 20-30 wt.% of polar solvents.
The waterborne coating solution in which the said silane based resin is having at least
one silane of the formula (1): R1Si (OR)3, wherein, R1 is a lower alkyl group (ethyl,
propyl), a phenyl group, R2 is a lower alkyl group (ethyl, methyl); and second resin is

having the formula (2). Both resins are cross-linked together (high polar groups) by
stirring with mechanical stirrer for 15 minutes and showing good binding and
adhesion promoting properties.

The waterborne coating solution comprising the aqueous solution of phosphorous
containing polyphenol (R3=Polyphenol-OH) is having the formula (3), which acts as a
catalyst to opening epoxy ring of GPTMS and convert into -OH group. This helps to
provide high functionality to react with the substrate. Due to the presence of
polyphenol with phosphorous, all available hydroxyl group is reacted to some quantity
of iron galvanneal sheet and form a passive film to prevent further oxidation of
surface. Formula (1) and (2) reacts in presence of aqueous solution of phosphorous
containing polyphenol and form a hybrid having the formula (4) as shown below.


The waterborne coating solution chemistry of base solution comprising of lower alkyl
alcohol based flowing and flexibilizer agent such as ethylene glycol or propylene glycol
(EG provide less flexibility due to its smaller carbon chain as compared to PG) which
increases the fluidity of total solution and polar solvents such as ethyl alcohol, iso-
propyl alcohol and butyl alcohol use as a viscosity and drying time reducer of the total
solution. This solution, now be modified by introducing some more additives such as
water based solution of acrylate copolymer reduces the surface tension and therefore
improves substrate wetting and prevents cratering and pinholes. Metal (barium) salt
based sulphonate are used as flash rust inhibitors having the formula 5a/5b.

The coating solution of the waterborne coating solution is a one type of solution which
can further be modified either by waterborne self-crosslinking acrylic copolymers such
as ALBERDINGK®AC 2773 (good binding properties) or water miscible acidic
polyethylene dispersion of wax particles such as luba print VP 499/A) for mar or slip
resistance and increasing lubricity as well in comparison with uncoated galvanneal
sheet.

These coating solutions may be applied by wiping, brushing, spraying and dipping.
The curing is done at 60-80 sec at 40-50° C as to provide a cross-linked and dense
structure of coating for improving corrosion resistance (salt spray test before cupping
test and after cupping test), fuel resistance, weld ability and formability as in Table 1.


Coating comprises the step of: (i) providing water-miscible polar organic solvents;
(ii). providing organic-inorganic hybrid silanes as a film forming and adhesion
promoters both;
(iii). Providing aqueous solution of phosphorous containing polyphenol as a corrosion
inhibitor and ring opening catalyst of film forming agent;
(iv). Providing metal salt based sulphonates as a flash rust inhibitor;
(v). flowing-flexibilizer agent with acrylate copolymers a surface tension reducer;
(vi). Modifying above solution either by lubricants or waterborne self-crosslinking
acrylic copolymers (good film binding properties) for improving mar/slip resistance
and lubricity;
(vii). Applying solution/ modified solution on galvanneal (GA) sheet by brushing/
rolling/ spraying/ dipping for improving corrosion resistance (salt spray test before
cupping test cupping test and after cupping test), fuel resistance, weld ability and
formability; vii. Curing within 60-80 sec at 40-50°C.
The present invention further relates to develop environment friendly coatings with
following characteristics:
i) Drying of the films (ASTM D5895-13): 60-80 sec within 40-50°C
ii) Coating thickness (Dry Film Thickness-ASTM E 376-11): <10um
iii) Corrosion resistance (ASTM B 117): >120hr
iv) Cross hatch adhesion test (ASTM D 3359-09): 4B/5B
v) Weldability (BS 1140): No extra sparking appears due to the coating.
vi) Solvent and fuel resistance (ASTM D 2792-69): hydrogen test fluid with
demineraized water having formic acid at ppm level.
vii) Deep drawing cup test (Formability: ISO 1520-2006): less friction of coated
samples as compare to uncoated galvannealed iron at all bank holding force.


In an embodiment of the invention a 10-15 wt. % coating mixture of silane based
comprising organic- inorganic adhesion promoter/ film forming resins such as methyl
tri methocy silane / propyl tri methoxy silane/ phenyl tri methocy silane/ methyl tri
ethocy silane with 3- glycidyloxysilane (1:1) with 3-10 wt. % aqueous solution of
phosphorous containing polyphenol as a corrosion inhibitor and ring opening catalyst
for resin (epoxy ring in inorganic-organic silane resin) for further reaction with
substrate surface.
In an embodiment of the invention, the coating mixture also comprises one or more of
the following compounds such as coating additives: 0.2-0.3 wt. % acrylic silicon based
leveling agents, 2-5 wt. % lower alkyl alcohol based flowing and flexibilizer agent such
as ethylene or prolylene glycol; 1-5.5 wt. % barium sulphonates as a flash rust
inhibitor.
In an embodiment of the invention, the coating mixture comprises 20-30 wt. % of
polar solvent such as iso-propyl alcohol, butyl alcohol, ethamol which are miscible
with remaining demineralized water, they are required for reduce the viscosity and
drying of the coating solution for easy applicability. This is a one inorganic-organic
hybrid silane based coating (HSC) having 3-4 pH.

In an embodiment, there is also another coating (HSCL) i.e., 98-99.5 wt. % of above
formed hybridsilane based coating with 0.5-2 wt. % water miscible acidic polyethylene
wax dispersion (a s a coating additive) is used for increasing the lubricity and lowering
the friction coefficient.
In an embodiment, there is also third one coating (HSCE) i.e., 70-90 wt. % of above
formed hybrid silane based coating with 10-30 wt. % water based self-crosslinking
acrylic copolymer (6pH) as a binder.
In the present invention, chemical boning of synthesized coating backbone is
described by FT-IR (Fourier transform- infrared spectroscopy) interpretation as shown
in Fig 1.
The band at 3379-6 cm1 is due to -OH stretching of the alcohol group (Si-OH, phenol).
The -C- H stretching peak (-CH2, -CH3) is observed at 2934 cm1 is due to the band at
1631.6 cm-1 is due to acrylic. Peak at 1268.7 cm1 is due to -C-O-(ethers). The strong
band at 1107.3 and 1036.0 cm-1 are due to Si-O-Si asymmetric stretching and Si-O-C
respectively. Si-C stretch vibrations arise at 796.7 cm-1 . Phosphorous with oxygen
(P=0, P-O) arises at 600.7 and 461.5 cm-1.
In applying the eco-friendly corrosion resistant thin organic coating compositions of
the invention to steel substrates (mainly on GA substrate), any of well-known coating
methods such as dipping, spraying, roll coating and brush coating may be employed.
These substrate curing is done at 60-80 sec @ 40-50°C as to provide a cross-linked
and dense structure of coating for improving corrosion resistance (due to the reaction
of phosphorous containing polyphenol with silane), fuel and solvent resistant (due to
the cross-linked structure of silane with P=0) and formability (due to the presence of
silicon and phosphorous). Although the coatihng weight of the composition is not
particularly limited, it is usually coated so as to give a coating thickness of 0.5u to
lOu with meeting all the objectives.
Example 1
In a first container, methyltrimethoxy silane (MTMS) and glycidyl propyl trimethioxy
silane (GPTMS) are mixed in amounts of 5 wt. % and 5 wt. % respectively. It is stirred

with mechanical stirrer for 15 minutes at high speed at room temperature. Both are
miscible and providing adhesion promotion with film forming capability. In second
container, water, Isopropyl alcohol and phosphorous containing polyphenol are mixed
in amount of 52.25 wt. %, 25 wt. % and 7 wt. % respectively. Second container's
solution is combined with first container while stirring gradually. After combining the
contents of the two containers, the resulting mixture is allowed at least 3 hours to
homogenize in ultra-sonication. Now this prepared solution has been stirred with 2 wt.
% of propylene glycol and 3.5 wt. % of metal slat based barium sulphonates flash rust
inhibitors. For improving leveling and wetting on substrate, the formed solution is
introduced by inserting 0.25 wt. % of water based solution of acrylate copolymer based
additive. The so-formed liquid mixture can be applied by wiping, brushing, spraying
and dipping on GA sheet. These substrate curing is done at 80 sec @ 40°C as to
provide a cross-linked and dense structure of coating for improving corrosion
resistance, weldability, fuel and solvent resistance and formability.
Details HSC
Inorganic-organic silane based resin GPTMS : MTMS (1:1) :10 wt. %(5:5)
Aqueous solution of phosphorous containing polyphenol : 7 wt. %
Metal salt based barium sulphonates flash rust inhibitors : 3.5 wt. %
Propylene glycol flowing-flexibilizer agent : 2 wt. %
Acrylate copolymer leveling agent : 0.25 wt. %
Iso-propyl alcohol : 25 wt. %
Demineralized water : 52.25 wt. %

Example 2
In a first container, propyl tri methicy silane (PTMS) provides more flexibility due to its
higher carbon number in hydrocarbon chain as compare to MTMS) and glycidyl propyl
trimethoxy silane (GPTMS) are mixed in amounts of 5 wt. % abd 5 wt. %respectively.
Both are miscible and providing adhesion promotion with film forming capability. It is
stirred with mechanical stirrer for 15 minutes at high speed at room temperature. In
second container, water, butyl alcohol and aqueous solution of phosphorous
containing polyphenol are mixed in amount of 5.75 wt. %, 25 wt. % and 5 wt. %
respectively. Second container's solution is combined with first container while stirring
gradually. After combining the contents of the two containers, the resulting mixture is
allowed at least 3 hours to homogenize in ultra-sonication. Now this prepared solution
has been stirred with 2 wt. % of ethylene glycol and 3.5 wt. % of metal salt based
barium sulphonates flash stirred rust inhibitors. For improving leveling and wetting
on substrate, the formed solution is introduced by inserting 0.25 wt. % of water based
solution of acrylate copolymer based additive. For reduction in friction coefficient (for
preventing its powdering during forming) on substrate, the formed solution is
introduced a 0.5 wt. % of water miscible acidic polyethylene wax dispersion (PE wax
dispersion) based lubricant (providing lubricity). The so-formed liquid mixture may be
applied by wiping, brushing, spraying and dipping. These substrate curing is done at
60 sec @ 50°C as to provide a cross-linked and dense structure of coating for
improving corrosion resistance, weldabilty, fuel and solvent resistance and formability.
Details HSC
Inorganic-organic silane based resin GPTMS : PTMS (1:1) :10 wt. %(5:5)
Aqueous solution of phosphorous containing polyphenol : 5 wt. %
Metal salt based barium sulphonates flash rust inhibitors : 3.5 wt. %
Ethylene glycol flowing-flexibilizer agent : 2 wt. %
Acrylate copolymer leveling agent : 0.25 wt. %
Butyl alcohol : 25 wt. %
PE wax dispersion : 0.5 wt. %
Demineralized water : 53.75 wt. %

Example 3:
In a first container, methyltrimethoxy silane and glycidyl propyl trimethoxy silane are
mixed in amounts of 5 wt. % and 5 wt. % respectively. Both are miscible and providing
adhesion promotion with film forming capability. It is stirred with mechanical stirred
for 15 minutes at high speed at room temperature. In second container, water,
ethanol, aqueous solution of phosphorous containing polyphenol and waterborne self-
crosslinking acrylic copolymer (It has good binding properties and provide a more
flexibility and lubricity of the solution) are mixed in amount of 4.25 wt. %, 25 wt. %, 4
wt. % and 15 wt. % respectively. Second container's solution is combined with first
container while stirring gradually. After combining the contents of the two containers,
the resulting mixture is allowed at least 3 hours to homogenize in ultra-sonication.
Now this prepared solution has been stirred with 2 wt. % of ethylene glycol (EG
provide less flexibility due to its smaller carbon chain as compared to PG). So we
introduce acrylic copolymer emulsion for increasing solution's flexibility) and 3.5 wt. %
of barium sulphonates flash rust inhibitors. For improving leveling and wetting on
substrate, the formed solution is introduced by inserting 0.25 wt. % of water based
solution of acrylate copolymer based additive. The so-formed liquid mixture may be
applied by wiping, brushing, spraying and dipping. These substrate curing is done at
60 sec @ 50°C as to provide a cross-linked and dense structure of coating for
improving corrosion resistance, weldability, fuel and solvent resistance and
formability.
Details HSC
Inorganic-organic silane based resin GPTMS : MTMS (1:1) :10 wt. %(5:5)
Waterborne self-crosslinking acrylic copolymer (Emulsion) : 15 wt. %
Aqueous solution of phosphorous containing polyphenol : 4 wt. %
Metal salt based barium sulphonates flash rust inhibitors : 3.5 wt. %
Ethylene glycol flowing-flexibilizer agent : 2 wt. %
Acrylate copolymer leveling agent : 0.25 wt. %
Etyle alcohol : 25 wt. %
Demineralized water : 40.25 wt. %

Fuel and solvent resistance test:
Uncoated and coated GA samples have been dipped for 1500 hours in testing solution.
Both hydrocarbon test fluid and aqueous solution of 3.5 % sodium chloride solutions
are immiscible to each other due to the polarity difference as shown in Fig 4.
Weld ability test (BS 1140):

Uncoated GA sheet (Thickness: 0.8 mm) having the nugget diameter from 3.15 to 4.40
in the range 6.5 to 7.0 Kilo ampere while other coated samples (Thickness: 3u) have
higher nugget diameter in the range of 6.5 to 7.5 Kilo ampere. There is an expulsion at
7.5 kilo ampere in uncoated GA but in coated samples expulsion will be taken place at
8.0 Kilo ampere so this is an indication of no sparking due to the coating (coating gives
way to the weld, thus allowing the parent metals to join and, at the same time,
keeping the coating intact between the electrodes and work piece) even it will help to
prevent the sparking during welding. So these coatings will support in welding.

Deep drawings cup test (Forming test: ISO 1520-2006)
Parameters for cupping test: Diameter of the coated and uncoated sample: 100 mm;
Punch diameter: 50 mm; Drawing Speed: 1.00mm; Thickness of GA sheet: 0.8mm;
Tensile strength of GA substrate: 314MPa; Yield strength: 177 MPa; Coating thicknes:
3u; Lubrication: 2 drop of Fucs oil at each side.
Generally, higher punch force indicates higher friction at fix blank holding force.
Example 1, 2 and 3 all show lower friction at 1, 2, 3 blank holding force as compare to
the uncoated GA but in example 2, it is minimum of the pack punch force as shown in
Fig 5. So all coatings will help to reduce the friction and provide the ease of forming.

WE CLAIM:
1. A waterborne coating solution comprising;
a silane-based resin (10-15 wt. %);
an aqueous solution of phosphorous containing polyphenol (3-10 wt. %);
an acrylic silicon based leveling agent (0.2-0.3 wt.%);
a lower alkyl alcohol based flowing and flexibilizer agent (2.5 wt.%);
a metal salt based barium sulphonates flash rust inhibitors (1-5.5 wt.%); and
polar solvents (20-30 wt.%).
2. The waterborne coating solution as claimed in claim 1, wherein the silane based
resin comprising of at least one silane of the formula (1) and a second resin of
the formula (2)

wherein R1 is a lower alkyl group such as ethyl, propyl or a phenyl group, R2 is
a lower alkyl group such as ethyl or methyl.

3. The silane based resin as claimed in claim 2, wherein both the resins are cross-
linked together by stirring with mechanical stirrer for 15 minutes.
4. The waterborne coating solution as claimed in claim 1, wherein the aqueous
solution of phosphorous contains polyphenol with formula 3,

wherein R3 = polyphenol-OH
5. A compound with Formula 4

wherein R3 = polyphenol-OH

6. The compound with formula 4 as claimed in claim 5, wherein the compound
with formula 4 is prepared by reacting formula I and formula II in presence of
solution of phosphorous containing polyphenol,

wherein R1 is a lower alkyl group such as ethyl, propyl or a phenyl group,
R2 is a lower alkyl group such as ethyl or methyl, and
R3 is polyphenol-OH.
7. The waterborne coating solution as claimed in claim 1, wherein the flowing and
flexibilizer agent can be selected from the group comprising ethylene glycol or
propylene glycol.
8. The waterborne coating solution as claimed in claim 1, wherein the polar
solvents can be selected from a group comprising of ethyl alcohol, iso-propyl
alcohol and butyl alcohol.

9. The waterborne coating solution as claimed in claim 1, wherein the metal
(barium) salt based sulphonates comprising of formula 5a or 5b,

wherein, the metal salts are used as flash rust inhibitors.
10. The waterborne coating solution as claimed in claim 1, wherein the solution
can be modified by introducing some more additives such as water based
solution of acrylate copolymer.
11. A waterborne coating solution as claimed in claim 1, wherein the coating
solution can be modified either by waterborne self-crosslinking acrylic
copolymers such as ALBERDINGK®AC 2773 or water miscible acidic
polyethylene dispersion of wax particles such as luba print VP 499/A).
12.The waterborne coating solution as claimed in claim 1-4 and claims 7-11,
wherein the coating solution may be applied by wiping, brushing, spraying and
dipping.

13. A process of coating comprising the step of:
(i) providing water-miscible polar organic solvents;
(ii) providing organic-inorganic hybrid silanes as a film forming and adhesion
promoters both;
(iii) providing aqueous solution of phosphorous containing polyphenol as a
corrosion inhibitor and ring opening catalyst of film forming agent;
(iv) providing metal salt based sulphonates as a flash rust inhibitor;
(v) flowing-flexibilizer agent with acrylate copolymers a surface tension reducer;
(vi) modifying above solution either by lubricants or waterborne self-
crosslinking acrylic copolymers (good film binding properties) for improving
mar/slip resistance and lubricity;
(vii) applying solution/ modified solution on galvanneal (GA) sheet by brushing/
rolling/ spraying/ dipping for improving corrosion resistance (salt spray test
before cupping test cupping test and after cupping test), fuel resistance, weld
ability and formability; and
(vii) curing within 60-80 sec at 40-50°C.