DESC:FIELD OF THE INVENTION
The present invention relates to method of preparing solvent borne epoxy resin. More specifically the present invention provides a method of preparation of solvent borne epoxy resin by reacting bisphenol A based epoxy resin or cycloaliphatic epoxy resin with amine, phenol novolac resin, and one more epoxy resin in suitable solvent or solvent mixture without using any catalyst. Advantageously, no byproduct is released in this process and the reaction is very straight forward. It gives over 1000 hours of salt spray data on mild steel (standard B-117) without using further additives. The resin is quick drying, highly flexible and has excellent adhesion on the mild steel.

BACKGROUND OF THE INVENTION:

Corrosion of metals nowadays is a big problem globally. The global cost of corrosion is estimated to be US$2.5 trillion annually which is equivalent to 3.4% of the global GDP as per report of financial times. The University of Edinburgh did a survey and they found that the estimated costs the UK spend for corrosion and wear approximately £80 billion per annum. Corrosion is a serious issue globally and it hampers the industrial ecosystem. Thus the viability of long term infrastructural assets can be hampered due to corrosion and due to the corrosion led pollution, the environment and ecosystem balance is deteriorated.

Corrosion is a major concern for metals like copper, mild steel, iron. In daily life we use all these metals in households like freezer, air conditioner, in vehicles, in industries. But the major problem is that they corrode easily when come in contact with air, moistures, environmental hazards. As a result, the durability of these metal parts reduced significantly.

Therefore, it is very essential to stop corrosion and application of protective coating is one of the option to counter this problem. Protective coating delays the corrosion significantly and thus saves the substance/substrate from pollution and economic loss.

References are invited for the prior arts related to the present invention.
US patent, provisional application No. 61/013,222; patent number US 2011/0049429 A1, filed on December, 2007 disclose, different glycidyl carbamate functional resins blended with different epoxy resins, and cured by amines. This is a two component system. The resins were applied on cold rolled Steel and cured by heating at 80 oC, for an hour. Dry film thickness was in between 11.2 – 154 micron. The SST data of different selected glycidyl carbamate resins compositions are tested for 1080 hours It was observed that the after above mentioned time of testing some corrosion were found as there is some rusting found on the panels. SST was done as per ASTM B117 standards.

In US 2010/0004355 A1, (Pub. Date: Jan. 7, 2010) an epoxy resin, an amine curing agent, and a hydroxyl group-containing coumarone resin were used for paint formulation. The resin was used for surface coating on pipelines under sea water. This resin is useful for the coating on the inside of a ship Such like ballast tank or similar kinds. This paint was air sprayed on a steel plate and dried at 23oC for 7 days. The dry film thickness was about 250 microns. The coating was characterized by flex resistance, impact resistance, salt water resistance, electric anticorrosion test, humidity resistance test.
In US 7,037,958 B1 (filed on October 10, 2003), an epoxy coating used as a nonskid surface for application such as deck of an aircraft carrier. The resin consists of an epoxy resin, epoxy containing toughening agent, an amine curing agent, rubber toughening agent, a corrosion inhibitor, and an optional fire retardant. It applied on a primer as topcoat. The average dry film thickness was in between 0.1 cm and 2 cm.
US 20030139559A1, (filed on November 12, 2002), discloses a moisture curable one component resin composition is provided which consists of a ketimine, an epoxy resin polymer and/or a silicone resin polymer containing at least two hydrolysable alkoxy sillyl groups. Although it is a one component system yet moisture curable, consequently it has some limitations in terms of application. It should be air tight always as there is a problem in stability in presence of moisture present in air.
US 20100297357A1 (filed on May 20, 2010), discloses that one component epoxy resin was prepared by reacting and epoxy resin containing 1,2 epoxy groups per molecule, a hydrocarbon containing softening point from 50oC to 140oC, an alkoxy functional and/or silanol-functional silicone, and a ketimine curing agent. This is again moisture curable one component resin. It means the resin should be kept air tight always otherwise stability issue would appear.
EP0584863A1 relates to a one pack self-curable epoxy resin composition comprising i) as epoxy component (a) at least one 1,2-epoxy resin compound having an average of more than one epoxy group per molecule and ii) as curing component (b) at least one reaction product obtainable by reacting at elevated temperature dicyandiamide with a tetrabromobisphenol-A type epoxy resin, said resin having an epoxide equivalent weight of from 330 to 1500 and a bromine content of from 10 to 50% by weight, and iii) as solvent (c) at least one compound being selected from the group represented by the general formula (I) wherein R¹, R², R4 and R5 each individually represent hydrogen or C1?3 alkyl, provided at least one of them is C1?3 alkyl, and R³ represents C1?3 alkyl.
EP0639599 relates to a water-free solvent system containing methoxy acetone and an organic protic solvent is useful as a solvent for a) a curing agent for an epoxy resin, such as a dicyandiamide and/or b) a curing catalyst and/or c) a cure inhibitor.
EP2432843A2 disclosed are high solids, one-component, storage stable coating compositions that include an epoxy resin comprising more than one 1,2-epoxy groups per molecule; a hydrocarbon compound having a softening point of from 50°C to 140°C; an alkoxy-functional and/or silanol-functional silicone; and a ketimine curing agent comprising a reaction product of reactants comprising a polyalkyldiamine component and a ketone component. Also disclosed are substrates at least partially coated with a coating deposited from such composition and methods for coating substrates with such compositions.
There are several types of protective coating, mainly water borne system and solvent borne system. Those may be one component or two component systems. The corrosion inhibition performance of Water borne systems are not as good as solvent borne system. Two component solvent borne systems have good anticorrosion performance but due to short pot life those are not user friendly. Hence there is still a need for a one component epoxy resin whose stability does not alter in the presence of air and offers anticorrosion performance like two component systems or close to two component systems.

OBJECT OF THE INVENTION:
It is thus the basic object of the present invention is to provide a one component epoxy resin which is curable both at ambient temperature (28-30 oC) to high temperature (120 oC or higher).
Another object of the present invention is to provide the resin which is quick drying and can be applied by spray coating, dip coating or brash coating after adjusting to suitable viscosity.
Yet another object of the present invention is to provide the resin which avoids curing by moisture with unaltered stability in the presence of air.
Final objective is to provide very good anticorrosive properties on mild steel and other metals like copper, galvanized iron.

SUMMARY OF THE INVENTION

In the primary embodiment the present invention is directed to provide a Solvent borne epoxy resin comprising reaction product of
a. phenol novolac resin (2-40%) grafted, amine (0.5 – 15%) modified aromatic epoxy resin (10-50%) and/or cycloaliphatic epoxy resin (10-50%) consisting of at least two aromatic rings; and
b. epoxy resin (2-30%) containing at least one aromatic ring or no aromatic ring;
c. and/or reactive epoxy diluents
providing ambient curing, quick drying coating composition wherein said solvent or solvent mixture includes methoxy propyl acetate, cellosolve acetate, butyl acetate, ortho xylene, mix xylene, hexylene glycol, ethyl carbitol, butyl carbitol, n-butanol, t-butanol, ethylene glycol monobutyl ether, diacetone alcohol and methyl isobutylketone or mixture thereof.
Another embodiment the present invention is directed to provide said Solvent borne epoxy resin suitable for one component coating wherein said aromatic epoxy resin of a. consisting of at least two aromatic rings is selected from YD-124, YD-125, YD-126, YD-127, YD-128, YD011x75, YD012x75, YD134x80, YD-901x75, YDF170, YDF-171, YDF172, YDF-173, YDFM-251, YDFM-270, YDFM-253, YDFM-261, YDFM-269, YDFM-262, YDFM-250, YDFM-256, YD-901, YD-902, YD-903, YD-904, YD-905, YD-907, YD-909, YD-012, YD-013, YD-014, YD-942, YD-972, YD-017, YD-019, YD-010S ;
said Cycloaliphatic epoxy resin includes ARCH-11, ARCH-12, ARCH-13, ARCH-13LV, ARCH-18;
said Epoxy reactive diluents includes RD-108, RD-109, RD-110, RD-118, RD-103, RD-111, RD-114, RD-119, RD-121, RD-133, RD-113, RD-124, RD-129, RD-131, RD-104, RD-105, RD-106, RD-136, RD-138, RD-137,
said Epoxy phenol novolac resin includes ARPN-25, ARPN-36, ARPN-36 M 80, ARPN-53, ARPN-54, YDPN – 638LV, YDPN-661, YDPN-638X80.

Yet another embodiment the present invention is directed to provide said Solvent borne epoxy resin wherein said epoxy resin containing at least one aromatic ring or no aromatic ring is selected from YD-124, YD-125, YD-126, YD-127, YD-128, YD011x75, YD012x75, YD134x80, YD-901x75, YDF170, YDF-171, YDF172, YDF-173, YDFM-251, YDFM-270, YDFM-253, YDFM-261, YDFM-269, YDFM-262, YDFM-250, YDFM-256, YD-901, YD-902, YD-903, YD-904, YD-905, YD-907, YD-909, YD-012, YD-013, YD-014, YD-942, YD-972, YD-017, YD-019, YD-010S and
said Epoxy reactive diluents includes RD-108, RD-109, RD-110, RD-118, RD-103, RD-111, RD-114, RD-119, RD-121, RD-133, RD-113, RD-124, RD-129, RD-131, RD-104, RD-105, RD-106, RD-136, RD-138, RD-137;
said amines used includes aniline, N-methyl aniline, triethylene tetramine, diethylene triamine, 2-butanamine, 3-methyl-1-butanamine, n-butylamine, n-octylamine, 2-aminoethanol, aminoethanoic acid, ethylene diamine, diethanolamine, 4-aminobenzoic acid, hexane-1,6-diamine, benzene-1,4-diamine, ethylamine, cyclohexyl amine, 2-methylbutylamine, (2-cyclooctylethyl)amine, (3-cyclopropylpentyl)amine, (3-metylpentyl) amine, (2-cycloheptylethyl)amine, tris-2aminoethylamine, bis(3-aminopropyl)amine.
Further embodiment the present invention is directed to provide said Solvent borne epoxy resin is quick drying as the surface dried within 15 min and hard dried within 24 hours, highly flexible and has excellent adhesion on the mild steel and copper, suitable for one component coating system without requiring any curing agent to get cured providing coating having average dry film thickness (DFT) in between 25 – 30 µ.
Still further embodiment the present invention is directed to provide said Solvent borne epoxy resin is comprised of polymeric particles having average particle size of 13.30 nm which signifies that the developed new polymers are nanomaterials;
when applied on galvanized iron (GI) and copper panel, the copper panel show excellent corrosion resistance and provide corrosion free copper panel up to 1000 hours,
whereas the GI panel is corrosion free until 300 hours, while at 600 hours, few white spots or white line on the cross cut appeared mainly due to the formation zinc oxide and zinc hydroxide, and after 1000 hours, the spots become little prominent and said white line thickness remains similar, without getting thick.

Another preferred embodiment the present invention is directed to provide a process for the preparation of Solvent borne epoxy resin comprising reaction product of
a. phenol novolac resin grafted, amine modified aromatic epoxy resin and/or cycloaliphatic epoxy resin consisting of at least two aromatic rings; and
b. epoxy resin containing at least one aromatic ring or no aromatic ring;
c. and/or reactive epoxy diluents as claimed in claims 1-5 comprising the steps of:
providing aromatic epoxy resin and/or cycloaliphatic epoxy resin in a solvent or solvent mixture and heating at elevated temp to get a clear solution;
adding the amine into the reaction mass at same temperature and reacted for three hours;
carrying out the reaction for 2-5 hrs after addition of the phenol novolac resin;
adding another epoxy resin and/or reactive epoxy diluents at elevated temperature and the reaction continued for 2-5 hrs;
diluting the reaction mixture with suitable solvent or solvent mixture to obtain the desired solid content and viscosity.

Yet further embodiment the present invention is directed to provide said process for the preparation of Solvent borne epoxy resin comprising
providing said aromatic epoxy resin (10-50%) and/or cycloaliphatic epoxy resin (10-50%) in a solvent or solvent mixture and heating at 80-100 oC to get a clear solution;
adding said amine (0.5 – 15%) into the reaction mass at same temperature and reacted for three more hours;
carrying out the reaction at 80-100 oC for three hours after addition of the phenol novolac resin (2-40%);
adding another epoxy resin (2-30%) and/or reactive epoxy diluents at 80-100 oC for reaction of three more hours;
diluting the reaction mixture with suitable solvent or solvent mixture to obtain the desired solid content and viscosity.

BRIEF DESCRIPTION OF THE NON-LIMITING ACCOMPANYING DRAWINGS:
Fig 1 illustrates the Salt spray test (SST) results of the resin prepared by the present invention on mild steel. Captured SST images represent the as such resin at different time intervals after drying at ambient temperature (28 – 30 oC) for seven days on mild steel. The average dry film thickness (DFT) of the coatings are in between 25 – 30 µ. The resin is spray coated after dilution to suitable viscosity. Cross cut on the coating is done to observe the corrosion around it with time.
Fig 2 illustrates the size distribution of the polymer material in 0.05% solution. The resin first dried in oven at 150 oC for 1 hour and then dissolved in suitable solvent. The particle size distribution of the resin then analyzed by Anton Paar LiteSizer 500 instrument. The particle size is taken as the average of three data.
Fig 3 illustrates the FTIR data of the dried sample recorded in the 4000 - 450 cm-1 range by making pellet with KBr.
Fig 4 illustrates the SST images of the as such resin at different time intervals after drying at ambient temperature (28 – 30 oC) for seven days on galvanized iron and copper. The average dry film thickness (DFT) of the coating was in between 25 – 30 µ. The resin was spray coated after dilution to suitable viscosity. Cross cut on the coating was done to observe the corrosion around it with time.

DETAILED DESCRIPTION OF THE INVENTION
The present invention thus relates to the solvent borne epoxy resin prepared by reacting bisphenol A based epoxy resin and/or cycloaliphatic epoxy resin with amine followed by phenol novolac resin, and finally with one more epoxy resin in suitable solvent or solvent mixture without using any catalyst and without releasing any byproduct. The epoxy resins used for synthesis may be modified if required.

The reaction is conducted in mixture of organic solvents at 80 - 100 oC. This is an exothermic reaction and no byproduct is released. The appearance of the resin is clear liquid with characteristic odor. This is one component system and does not require any curing agent to get cured. The resin is quick drying and it surface dried within 15 min and hard dried within 24 hours.

As stated hereinbefore several types of protective coating, mainly water borne system and solvent borne system are available/reported. Those may be one component or two component systems. The corrosion inhibition performance of Water borne systems are not as good as solvent borne system. Two component solvent borne systems have good anticorrosion performance but due to short pot life those are not user friendly. Therefore, if it is possible to prepare a one component solvent borne system which gives anticorrosion performance like two component systems or close to two component systems would be very beneficial for end applications.

Keeping that in mind, the present invention offers a one component solvent borne epoxy based anticorrosion resin which displays good anticorrosion performance on mild steel, copper, and galvanized iron. The method to synthesize the resin is very simple and the reaction does not release any byproduct as well as does not require any catalyst. Apart from the above, the resin has good stability in air, it does not cure in the presence of moisture like other one component solvent borne systems. It can be applied on metal surface by spraying, dipping, or brushing after adjusting to suitable viscosity.

The epoxy resins used in this invention are either commercially available epoxy resins or modified as per requirement. Two or more epoxy resins have also been used successfully in this invention. Generally, epoxy resins may be bisphenol epoxies or modified bisphenol epoxies, cycloaliphatic epoxies or modified cycloaliphatic epoxies, novolac resins, epoxy reactive diluents or modified epoxy reactive diluents, monoamines or diamines or polyamines. Amines may be linear or cyclic.
The epoxy resins for the present invention includes aromatic epoxy resins, cycloaliphatic epoxy resins, phenol novolac resins, Epoxy diluent, amines.

Aromatic epoxy resins include YD-124 (Modified Bisphenol-A based Liquid Epoxy Resin; Low viscosity; Free of reactive diluents and solvents; High crystallization resistance), YD-125, YD-126, YD-127, YD-128, YD011x75, YD012x75, YD134x80, YD-901x75, YDF170, YDF-171, YDF172, YDF-173, YDFM-251, YDFM-270, YDFM-253, YDFM-261, YDFM-269, YDFM-262, YDFM-250, YDFM-256, YD-901, YD-902, YD-903, YD-904, YD-905, YD-907, YD-909, YD-012, YD-013, YD-014, YD-942, YD-972, YD-017, YD-019, YD-010S. These resins are procured from Epotec India.

Cycloaliphatic epoxy resin includes ARCH-11, ARCH-12, ARCH-13, ARCH-13LV, ARCH-18 and are procured from Atul India.

Epoxy reactive diluents includes RD-108, RD-109, RD-110, RD-118, RD-103, RD-111, RD-114, RD-119, RD-121, RD-133, RD-113, RD-124, RD-129, RD-131, RD-104, RD-105, RD-106, RD-136, RD-138, RD-137. These reactive diluents are procured from Epotec India.

Epoxy phenol novolac resin includes ARPN-25, ARPN-36, ARPN-36 M 80, ARPN-53, ARPN-54, YDPN – 638LV, YDPN-661, YDPN-638X80. These resins are procured from either Epotec or Atul, India.

The amines used for the present invention is/are selected from aniline, N-methyl aniline, triethylene tetramine, diethylene triamine, 2-butanamine, 3-methyl-1-butanamine, n-butylamine, n-octylamine, 2-aminoethanol, aminoethanoic acid, ethylene diamine, diethanolamine, 4-aminobenzoic acid, hexane-1,6-diamine, benzene-1,4-diamine, ethylamine, cyclohexyl amine, 2-methylbutylamine, (2-cyclooctylethyl)amine, (3-cyclopropylpentyl)amine, (3-metylpentyl)amine, (2-cycloheptylethyl)amine, tris-2aminoethylamine, bis(3-aminopropyl)amine. These are procured from various sources.

The solvent or solvent mixture may be methoxy propyl acetate, cellosolve acetate, butyl acetate, ortho xylene, mix xylene, hexylene glycol, ethyl carbitol, butyl carbitol, n-butanol, t-butanol, ethylene glycol monobutyl ether, diacetone alcohol, methyl isobutylketone.

The curing of as such resin coating for salt spray test and water dip test is done at ambient temperature (28 – 30 oC) for 168 hours. The film of the polymer coated on mild steel/copper are prepared by spraying the polymer solution using a spray gun after proper dilution with solvent. The cured coating was subjected to different tests to evaluate the performance of the same as follows:

i. Water dip test results show no spots, no blistering, no swelling after 168 hours.

ii. Cross cut adhesion test using Zehntner testing instrument (model no. ZMG 2151) shows 5B adhesion (as per ASTM D 3359).

iii. Flexibility test (as per ISO/IEC 17025 calibration lab) shows no crack or flake of the film around the bend part of the coating.

iv. Salt spray testing result (ASTM B117 standard) of as such clear film without any additive on mild steel showed no sign of rusting, flaking, or spots on the coating after 500 hours. Along the cross cut, there was negligible rusting shown around. After 1000 hours, the rusting around the cross cut was little thicker otherwise the coating was mostly okay. At the edges where black tape was attached, a brown shade was observed mainly due to the leakage of moisture through black tape after several hundred hours of SST catches the bare metal and the wash out of the bare metal spread over the coating. As a result, those part got brown color.

v. The particle size distribution is shown in the figure 2. Three different samples are taken for the determination of particle size and their average are taken as average particle size. The average particle size are found to be 13.30 nm. It means that the developed new polymers are nanomaterials.

vi. The FTIR spectra is shown in Figure 3. The broad peak observed in between 3550 – 3200 cm-1 is mainly due to OH stretching frequency. The small peak observed in between 3100 – 3000 cm-1 is probably due to sp2 CH stretching. The peak observed in between 3000 – 2800 cm-1 is mainly due to sp3 C-H stretching. The peak around 1606 cm-1 may be due to aromatic C=C bending. The peak observed at 1508 cm-1 may be N-O stretching. The peak observed around 1229 cm-1 may be due to C-O stretching of alkyl aryl ether. The peak observed around 1035 cm-1 is probably due to C-N stretching of amine. The peak appeared around 824 cm-1 probably due to sp3 C-H bending.

vii. The SST (ASTM B117) data on galvanized iron (GI) and copper panel are shown in figure 4. From the figure it is evident that, the corrosion resistance of this coating on copper are excellent. On GI panel, up to 300 hours, there is no corrosion observed. At 600 hours, some white spots observed. Along cross cut, white line appears. The white spots and lines are mainly due to the formation zinc oxide and zinc hydroxide. After 1000 hours, the spots are little prominent and said white line thickness remains similar, without getting thick.

EXAMPLEs:

EXAMPLE 1: METHOD OF PREPARATION

In a four neck round bottom flask, a bisphenol A type epoxy resin (Epoxy equivalent 190 -2000 g/mol) (10-50%, or more precisely 20-50% or even more precisely 20-45%) is dissolved in an alcoholic hydrocarbon solvent mixture and dissolved it by heating at 80-100 oC. Then an alcoholic amine (0.5 – 15%) added to it at the same temperature and reacted for three hours. After that, a phenol novolac resin (2-40%, or more precisely 2-15% or even more precisely 2-12%) is added to it at 80-100 oC and reacted for three hours. Finally, another epoxy resin (2-30%, or more precisely 2-15% or even more precisely 2-10%) having at least one epoxy group are reacted with it at 80-100 oC for three more hours. After reaction is complete, the reaction mixture was diluted with alcoholic hydrocarbon solvent mixture to obtain the desired solid content and viscosity.

Method of preparation (Comparative)
In a four neck round bottom flask, a bisphenol A type epoxy resin (Epoxy equivalent 450 -1500 g/mol) (10-50%, or more precisely 20-50% or even more precisely 20-40%) is dissolved in an alcoholic solvent and dissolved it by heating at 80-100 oC. Then a polyether type amine (0.5 – 20%, or more precisely 0.5-15% or even more precisely 0.5 -12%) added to it at same temperature and reacted for three hours. After that, the phenol novolac resin (2-40%, or more precisely 2-15% or even more precisely 2-12%) is added to it at 80-100 oC After one hour of reaction, the gelation tendency observed. From this result it is understandable that the choice of suitable reagents, suitable solvents are very crucial to obtain optimum cross-linking in order to make a stable resin. If the select conditions are maintained, stable resin will be formed and desired property will be achieved.

EXAMPLE 2: Salt spray test (SST) result

As stated hereinbefore the curing of as such resin coating for salt spray test and water dip test is done at ambient temperature (28 – 30 oC) for 168 hours. For cross cut adhesion and flexibility test, the coating is cured at ambient temperature (28 – 30 oC) for 72 hours. The average dry film thickness of the coating is 25-30 µ for all the testing. The film of the polymer coated on mild steel/copper are prepared by spraying the polymer solution using a spray gun after proper dilution with solvent.

The effect of SST upon as such resin coating is shown in the Figure 1. From the images, it is evident that in the first 500 hours there is hardly any spots observed on the panel. Along the cross-cut section also rusting did not spread. After 600 hours of SST, a slight brown shade observed above and below portion of the cross-cut. This is mainly due to the fact that the bare mild steel panel got exposed through the black tape after 600 hours of SST and the wash out rolls over coating gives a brown shade. Similarly, from the cross-cut section wash comes out from the exposed metal which gives the brown shade. But the coating remains intact. When the SST time goes up to 1000 hours, the brown shade becomes more prominent as the metal getting more exposed with time. Rusting along cross-cut also getting thicker over time. But the overall coating does not change much.

The SST (ASTM B117) data on galvanized iron (GI) and copper panel are shown in figure 4. From the figure it is evident that, the copper panel did not corrode at all up to 1000 hours. It means the corrosion resistance of this coating on copper are excellent. On GI panel, up to 300 hours, there is no corrosion observed. At 600 hours, some white spots observed. Along cross cut, white line appears. The white spots and lines are mainly due to the formation zinc oxide and zinc hydroxide. After 1000 hours, the spots are little prominent and said white line thickness remains similar, without getting thick.

Thus the present invention provides a Solvent borne epoxy resin and its method of preparation wherein the resin is quick drying, highly flexible and has excellent adhesion on the mild steel and copper wherein the method for preparation is simple and free of any by product release.
,CLAIMS:We Claim

1, Solvent borne epoxy resin comprising catalyst free reaction product of
a. phenol novolac resin (2-40%) grafted, amine (0.5 – 15%) modified aromatic epoxy resin (10-50%) and/or cycloaliphatic epoxy resin (10-50%) consisting of at least two aromatic rings; and
b. epoxy resin (2-30%) containing at least one aromatic ring or no aromatic ring;
c. and/or reactive epoxy diluents
providing ambient curing, quick drying coating composition wherein said solvent or solvent mixture includes methoxy propyl acetate, cellosolve acetate, butyl acetate, ortho xylene, mix xylene, hexylene glycol, ethyl carbitol, butyl carbitol, n-butanol, t-butanol, ethylene glycol monobutyl ether, diacetone alcohol and methyl isobutylketone or mixture thereof.
2. The Solvent borne epoxy resin as claimed in claim 1 suitable for one component coating wherein said aromatic epoxy resin of a. consisting of at least two aromatic rings is selected from YD-124, YD-125, YD-126, YD-127, YD-128, YD011x75, YD012x75, YD134x80, YD-901x75, YDF170, YDF-171, YDF172, YDF-173, YDFM-251, YDFM-270, YDFM-253, YDFM-261, YDFM-269, YDFM-262, YDFM-250, YDFM-256, YD-901, YD-902, YD-903, YD-904, YD-905, YD-907, YD-909, YD-012, YD-013, YD-014, YD-942, YD-972, YD-017, YD-019, YD-010S ;
said Cycloaliphatic epoxy resin includes ARCH-11, ARCH-12, ARCH-13, ARCH-13LV, ARCH-18;
said Epoxy reactive diluents includes RD-108, RD-109, RD-110, RD-118, RD-103, RD-111, RD-114, RD-119, RD-121, RD-133, RD-113, RD-124, RD-129, RD-131, RD-104, RD-105, RD-106, RD-136, RD-138, RD-137,
said Epoxy phenol novolac resin includes ARPN-25, ARPN-36, ARPN-36 M 80, ARPN-53, ARPN-54, YDPN – 638LV, YDPN-661, YDPN-638X80.

3. The Solvent borne epoxy resin wherein said epoxy resin containing at least one aromatic ring or no aromatic ring as claimed in claims 1-2 is selected from YD-124, YD-125, YD-126, YD-127, YD-128, YD011x75, YD012x75, YD134x80, YD-901x75, YDF170, YDF-171, YDF172, YDF-173, YDFM-251, YDFM-270, YDFM-253, YDFM-261, YDFM-269, YDFM-262, YDFM-250, YDFM-256, YD-901, YD-902, YD-903, YD-904, YD-905, YD-907, YD-909, YD-012, YD-013, YD-014, YD-942, YD-972, YD-017, YD-019, YD-010S and
said Epoxy reactive diluents includes RD-108, RD-109, RD-110, RD-118, RD-103, RD-111, RD-114, RD-119, RD-121, RD-133, RD-113, RD-124, RD-129, RD-131, RD-104, RD-105, RD-106, RD-136, RD-138, RD-137;
said amines used includes aniline, N-methyl aniline, triethylene tetramine, diethylene triamine, 2-butanamine, 3-methyl-1-butanamine, n-butylamine, n-octylamine, 2-aminoethanol, aminoethanoic acid, ethylene diamine, diethanolamine, 4-aminobenzoic acid, hexane-1,6-diamine, benzene-1,4-diamine, ethylamine, cyclohexyl amine, 2-methylbutylamine, (2-cyclooctylethyl)amine, (3-cyclopropylpentyl)amine, (3-metylpentyl) amine, (2-cycloheptylethyl)amine, tris-2aminoethylamine, bis(3-aminopropyl)amine.

4. The Solvent borne epoxy resin as claimed in claims 1-3 is quick drying as the surface dried within 15 min and hard dried within 24 hours, highly flexible and has excellent adhesion on the mild steel and copper, suitable for one component coating system without requiring any curing agent to get cured providing coating having average dry film thickness (DFT) in between 25 – 30 µ.

5. The Solvent borne epoxy resin as claimed in claims 1-4 is comprised of polymeric particles having average particle size of 13.30 nm which signifies that the developed new polymers are nanomaterials;
when applied on galvanized iron (GI) and copper panel, the copper panel show excellent corrosion resistance and provide corrosion free copper panel up to 1000 hours,
whereas the GI panel is corrosion free until 300 hours, while at 600 hours, few white spots or white line on the cross cut appeared mainly due to the formation zinc oxide and zinc hydroxide, and after 1000 hours, the spots become little prominent and said white line thickness remains similar, without getting thick.

6. A process for the preparation of Solvent borne epoxy resin comprising reaction product of
a. phenol novolac resin grafted, amine modified aromatic epoxy resin and/or cycloaliphatic epoxy resin consisting of at least two aromatic rings; and
b. epoxy resin containing at least one aromatic ring or no aromatic ring;
c. and/or reactive epoxy diluents as claimed in claims 1-5 comprising the steps of:
providing aromatic epoxy resin and/or cycloaliphatic epoxy resin in a solvent or solvent mixture and heating at elevated temp to get a clear solution;
adding the amine into the reaction mass at same temperature and reacted for three hours;
carrying out the reaction for 2-5 hrs after addition of the phenol novolac resin;
adding another epoxy resin and/or reactive epoxy diluents at elevated temperature and the reaction continued for 2-5 hrs;
diluting the reaction mixture with suitable solvent or solvent mixture to obtain the desired solid content and viscosity.

7. The catalyst free process for the preparation of Solvent borne epoxy resin as claimed in claim 6 comprising
providing said aromatic epoxy resin (10-50%) and/or cycloaliphatic epoxy resin (10-50%) in a solvent or solvent mixture and heating at 80-100 oC to get a clear solution;
adding said amine (0.5 – 15%) into the reaction mass at same temperature and reacted for three more hours;
carrying out the reaction at 80-100 oC for three hours after addition of the phenol novolac resin (2-40%);
adding another epoxy resin (2-30%) and/or reactive epoxy diluents at 80-100 oC for reaction of three more hours;
diluting the reaction mixture with suitable solvent or solvent mixture to obtain the desired solid content and viscosity.

Dated this the 4th day of March, 2024 Anjan Sen
Of Anjan Sen and Associates
(Applicants Agent)
IN/PA-199