FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
AND
THE PATENT RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
“SOLVENT-FREE ANTICORROSIVE EPOXY RESIN COMPOSITION FOR
COATING”
We, ATUL LIMITED, an Indian Company, of P.O. - Atul, District - Valsad PIN-396020, Gujarat, India; and
INDIAN NAVY, an Indian National, of Oi/C TDAC, DSR, A Block Hutments, Dara Shukoh Road, New Delhi 110 001.
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
The present invention relates to the technical field of coatings, and in particular relates to a solvent free coating composition and a preparation method thereof. More particularly, the present invention relates to the coating composition, which may include, without limitation, a resin component and curing agent component and optionally includes one or more of a dispersing agent, pigment, rheology modifier or other additives. The said anticorrosive coating composition also has anti-skid property. The composition has application for coating of the upper surfaces of ships, boats and other similar structures.
BACKGROUND OF THE INVENTION
Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
Marine corrosion is a major hazard for the industry. Marine corrosion refers to the breakdown or degradation of metallic materials due to an electrochemical reaction when the surrounding environment (e.g., ocean, lake, sea) contains a naturally high salt moisture content. The deterioration of these structures causes higher maintenance costs, early system failures, or an overall shortened service life. Efforts to mitigate corrosion in marine environments continue as industries develop and implement solutions to prevent asset degradation.
Despite the clear problem of corrosion, the prior art has failed to address and solve the problem of providing an effective anti-corrosive coating to the different surfaces of ships, boats and other similar marine structures, which is having a long time durability in such a harsh marine conditions. The need for an effective anti-corrosive coating solution that will not alter the anti-corrosive property in both dry and wet conditions.

There have been several attempts in the prior art to mitigate the problem of corrosion of the surfaces of marine structures. Patent application WO2019185876 discloses a new structural class of phenalkamines, curing agent compositions comprising the phenalkamines, their use, as well as and methods of producing such phenalkamines by reacting cardanol with an aldehyde compound and triaminononane.
Patent application US20200354604 discloses an epoxy resin composition comprising at least one epoxy liquid resin, bis(aminomethyl)cyclohexane and a wax, wherein the wax contains long-chain fatty acid esters and/or long-chain hydrocarbons having a molecular weight in the range from 250 to 1000 g/mol.
Patent US7037958 discloses an epoxy topcoat comprising a cured mixture having an epoxy resin, an epoxide-containing toughening agent, optionally, an UV light stabilizer, a pigment, a glass fiber thixotrope and impact toughening agent, an optional abrasive aggregate, an optional fire retardant, an amine curing agent, and a rubber toughening agent other than the epoxide-containing toughening agent.
Patent CN111454646 discloses high-brightness two-component marking paint comprises Part (A) having epoxy active diluent, ethanol, modified bisphenol-A epoxy resin, titanium dioxide and fluorescent powder; and Part (B) having dioctyl phthalate, modified aliphatic amine epoxy curing agent, epoxy accelerator, calcium carbonate, and UV absorbent.
Patent CN111334166 discloses high-temperature and high-pressure resistant solvent-free heavy anti-corrosion paint comprising Part (A) having phenolic epoxy resin, bisphenol-F resin, a reactive toughening agent, an active diluent, a thixotropic agent, a heat-resistant pigment, an auxiliary agent and filler and Part (B) having a curing agent and is a mixture of modified fatty amine and modified phenolic aldehyde amine.

Patent CN111117424 discloses an epoxy resin gel coat composition having an Epoxy resin component and an amine curing agent component. The weight ratio of the Epoxy resin component to the amine curing agent component is 100: (15-25) and said Epoxy resin component includes liquid Epoxy resin, color paste, non-halogen flame retardant and auxiliary.
However, there is still a need for a specific anti-corrosive floor coating composition, applicable for different surfaces of ships, boats and other marine structures along with having a problem solution approach with respect to the prior art. That composition should have the qualities of being aesthetically pleasing and easy and safe to apply, and maintain.
OBJECTS OF THE INVENTION
The main object of the present invention is to provide a solvent-free epoxy coating composition used as anti-corrosive coat on different surfaces, including upper deck surface, of ships, boats or other similar marine structures.
Accordingly, it is an object of the present invention to provide a coating composition which is highly corrosion resistant when dry or wet.
Another object of the present invention is to provide a floor coating that has a sufficiently uniform appearance and corrosion resistant throughout.
Another object of the present invention is to provide a coating composition that is easy and safe to apply and easy to clean and maintain.
Another object of the present invention is to provide an epoxy coating composition that it is excellent in adhesion to the object to be coated and corrosion resistance.

Another object of the present invention is to provide an anti-corrosive epoxy coating composition that it is thin layered when applied and due to this it also not increasing the overall weight of that ship or boat.
Another object of the present invention is to provide an anti-corrosive epoxy coating composition that it sufficient to apply only a single coat and having a good performance.
The other objects and preferred embodiments and advantages of the present invention will become more apparent from the following description of the present invention when read in conjunction with the accompanying examples, which are not intended to limit scope of the present invention in any manner.
SUMMARY OF THE INVENTION
The principal aspect of the present invention is to provide a solvent-free epoxy anti-corrosive coating composition and a manufacturing method thereof.
One aspect of the present invention relates to a solvent-free epoxy anti-corrosive coating composition comprising a resin component (A), and a curing agent component (B), wherein component (A) comprises: 54-62 % by weight of binder; 8-12 % by weight of reactive diluent; 4-6 % by weight of anti-corrosive pigment; 12-16 % by weight of filler; 5-10 % by weight of opacity provider; 0.5-1.0 % by weight of organic pigment; 0.5-1.0 % by weight of wetting and dispersing additive; 0.30-0.80 % by weight of rheology modifier; 0.1-0.5 % by weight of defoamer; 1.0-2.0 % by weight of adhesion promoter; and 1.5-2.5 % by weight of flexibility additive; and wherein component (B) comprises 85-95 % by weight of cardanol based curing agent; 3.0-8.0 % by weight of low viscosity reactive polyamide; and 3.0-8.0 % by weight of accelerator.
Another aspect of the present invention relates to a solvent-free epoxy anti-corrosive coating composition comprising a resin component (A), and a curing

agent component (B), wherein component (A) and component (B) is uniformly mixed in a suitable ratio before applying to the target surface.
In another aspect of the present invention is directed to a method of preparing a solvent-free epoxy anti-corrosive coating composition comprising:
Preparation of Component (A): In a clean bead mill, add binder, reactive diluent, wetting and dispersing additive and rheology modifier. After mixing for 5-10 minutes, add anti-corrosive pigment, opacity provider, organic pigment and filler. Disperse for 60 minutes at 6-7 m/s tip speed. After achieving desired dispersion, stabilized with part of epoxy resin and reactive diluent. Discharge stabilized mill base in high speed mixture and add defoamer, adhesion promoter and flexibility additive to finish the batch. Mixed for 30 minutes and packed in drum after filtration.
Preparation of Component (B): cardanol based curing agent, low viscosity reactive polyamide and accelerator are mixed well at 40-50°C temperature in reactor. After mixing, packed in drum after filtration.
For application, Component (A) and Component (B) are uniformly mixed in a ratio ranging from 2:1 to 10:7 by volume, preferably in a ratio of 5:3 by volume.
DETAILED DESCRIPTION OF THE INVENTION
The following is a detailed description of embodiments of the disclosure. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.

Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims.
As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
The present invention provides a process and composition for forming an anti-corrosive coating upon a substrate. In a preferred embodiment, the

composition forms a protective coating on different surfaces of a ship, boat or similar marine structures. In a highly preferred embodiment, the composition preferably includes at least two components: A) resin component and B) hardener component.
An illustrative composition comprising various ingredients and its weight percentage range is illustrated in the table below:

S.N.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11. Component A

Ingredient Weight % Range

Binder 54-62%

Reactive diluent 8-12%

Anti-corrosive pigment 4-6%

Filler 12-16%

Opacity provider 5-10%

Organic Pigment 0.5-1.0%

Wetting and dispersing additive 0.5-1.0 %

Rheology modifier 0.30-0.80%

Defoamer 0.1-0.5%

Adhesion Promoter 1.0-2.0%

Flexibility additive 1.5-2.5%

S.N.
1. 2. 3. Component B

Ingredient Weight % Range

Cardanol based curing agent 85-95%

Low viscosity reactive polyamide 3.0-8.0%

Accelerator 3.0-8.0 %
In an embodiment, the anti-corrosive coating composition of the present invention is directed to a method of preparing comprising:
1) Preparation of Component (A): In a clean bead mill, add binder, reactive diluent, wetting and dispersing additive and rheology modifier. After mixing for 5-10 minutes, add anti-corrosive pigment, opacity provider, organic pigment and filler. Disperse for 60 minutes at 6-7 m/s tip speed. After achieving desired dispersion, stabilized with part of binder and reactive diluent. Discharge stabilized mill base in high speed mixture and add defoamer, adhesion promoter and flexibility additive to finish the batch. Mixed for 30 minutes and packed in drum after filtration.
2) Preparation of Component (B): In a reactor, add cardanol based curing agent, low viscosity reactive polyamide and accelerator followed by proper mixing at 40-50°C temperature. After mixing, packed in drum after filtration.
3) For application, the component (A) and the component (B) are uniformly mixed in a ratio ranging from 2:1 to 10:7 by volume, preferably in a ratio of 5:3 by volume of component (A) and component (B) respectively and used.
In a preferred embodiment, both component (A) and component (B) of the anti-corrosive coating composition of the present invention is free from any solvent.

In an embodiment, the binder is an epoxy resin, based on Bisphenol A or Bisphenol F, which includes, but is not limited to, bisphenol A-epichlorohydrin epoxy resin, bisphenol F-epichlorohydrin epoxy resin, diglycidyl ether of novolac resin, hydrogenated bisphenol A, F or A/F epoxy resin, preferably bisphenol A-epichlorohydrin epoxy resin.
In a preferred embodiment, the epoxy resin may be a single resin. In another preferred embodiment, the epoxy resin is a mixture of mutually compatible epoxy resins.
In an embodiment, reactive diluent includes, but is not limited to, glycidyl ethers of phenols, cresols, alkyl phenols, butanol, C10 to C14 alcohols or mixture thereof. Examples of reactive diluents are, but not limited to,phenylglycidyl ether, butylglycidyl ether, allylglycidyl ether or butanediol diglycidyl ether. Prefereably, the reactive diluent is phenylglycidyl ether.
In an embodiment, anti-corrosive pigment includes, but is not limited to, zinc phosphate, calcium phosphate, calcium magnesium orthophosphate, zinc aluminum orthophosphate, zinc chromate, zinc molybdate, aluminum molybdate, aluminum tripolyphosphate, magnesium oxyaminophosphate or mixtures thereof. In a preferred embodiment, the anti-corrosive pigment is zinc phosphate.
In an embodiment, filler includes, but is not limited to, barium sulfate, silica, alumina, silicates, hydrated magnesium silicate (or talc), hydrated potassium aluminum silicate, kaolin, glass flakes, calcium sulfate, micaceous iron oxide, or mixtures thereof. In a preferred embodiment, the filler is barium sulfate.
In an embodiment, opacity provider includes, but is not limited to, rutile titanium dioxide, zinc oxide, or mixtures thereof. In a preferred embodiment, the opacity provider is rutile titanium dioxide.
In an embodiment, organic pigment includes, but is not limited to, carbon black, white lead, graphite, zinc sulfide, chromium oxide, yellow nickel titanium, yellow chromium titanium, yellow iron oxide, red iron oxide, black iron oxide,

phthalocyanine blue, phthalocyanine green, ultramarine blue, benzimidazolone yellow, quinacridone red, azo red/yellow pigments, and the like or mixture thereof.
In an embodiment, wetting and dispersive additive includes, but is not limited to, suitable conventional low or high molecular weight polycarboxylic acid, polyacrylate, polyurethane or salt of unsaturated polyamine amide and polyester polymers. Non-limiting examples of wetting and dispersive additives include commercially available products such as BYK-9076®, Anti-Terra-U100®, Tego® Dispers 652, 685, EFKA® FA 4611 etc,. In a preferred embodiment, the wetting and dispersive additive is BYK-9076®.
In an embodiment, rheology modifier includes, but is not limited to, polyamide wax, organo clay, aluminium stearate, hydrogenated castor oil wax, oxidized polyethylene, polyether phosphate, fumed silica and mixtures thereof. Non-limiting examples of rheology modifiers include Disparlon® 6650,6600, 6700, or RHEOBYK-7502®. In a preferred embodiment, the rheology modifier is Disparlon® 6650.
In an embodiment, defoamer includes, but is not limited to, organo-modified polysiloxane, modified silicone, mineral oil, fluorocarbon or vinyl and acrylic based suitable defoamer, and mixtures thereof. Non-limiting examples of defoamer include hydroxy group-containing dimethylsiloxanes, commercially available products such as Tego Airex® 900, 990, BYK 1760, Efka® PB 2744 etc,. In a preferred embodiment, the defoamer is Tego Airex® 900.
In an embodiment, one or more adhesion promoters include, but is not
limited to, bis(trialkoxysilylalkyl)amines, N, N'-
bis(trialkoxysilylalkyl)alkylenediamines, gamma-glycidoxypropyl trimethoxy silane,
2-[[3-(trimethoxysilyl) propoxy] methyl]oxirane, an amino silane, e.g. N-(2-
aminoethyl)-3-aminopropyltrirnethoxysilane, in combination with an
organomodified siloxane. Examples of suitable adhesion promotors are
commercially available products like Silane A187®, Dynasylan 1124®, Silquest A-
1170® 1120, SIB1824.5®, SIB1834.1®, Dynasylan GLYMO®, Dow Corning Z -6020®

or mixture thereof. In a preferred embodiment, the adhesion promoter is Silane A187® or 2-[[3-(trimethoxysilyl) propoxy] methyl]oxirane.
In an embodiment, one or more flexibility cum toughening agent is selected from the group consisting of suitable conventional chlorinated paraffin wax or polyvinyl butyral resin.
In an embodiment, cardanol based curing agent includes, but is not limited to, modified polyamine, phenalkamine or cashew nutshell oil polymer with formaldehyde and ethylenediamine or diethylenetriamine or triethylenetetramine or meta-xylenediamine.
In an embodiment, low viscosity reactive polyamide includes, but is not limited to, the reaction product of aliphatic polyamines (diethylenetriamine or triethylenetetramine, tetraethylenepentamine or pentaethylenehexamine) with dimer acids made by Diels-Alder reaction of linoleic and oleic fatty acids. Examples of suitable reactive polyamide are commercially available products like Polyamide-160®, Versamid® 140, Disvamide®-66025 etc.
In an embodiment, accelerator includes, but is not limited to, 2,4,6-
tris(dimethylaminomethyl)phenol, triethanolamine (TEA) or N,N-
Dimethyldipropylenetriamine preferably 2,4,6-tris(dimethylaminomethyl)phenol.
The present invention entails a corrosion resistant surface coating composition that is designed and formulated to be applied to any required surfaces of a ship. Apart from this, the coating composition of the present invention also has anti-skid application through addition of quartz sand while application. When applied to a deck surface, the present coating composition mixed with quartz sand provide an excellent slip-resistant coating to the floor or surface.
In an embodiment of the present invention, the composition further comprises quartz sand of 30-80 mesh size in an amount ranging from 0.5kg to 1.5kg per liter of anti-corrosive coating composition for imparting anti-skid feature.

In another embodiment of the present invention, the anti-corrosive coating composition can be applied in a conventional manner by using techniques familiar to a person skilled in the art. Suitable techniques of application include, but are not limited to brushing, using compatible notched trowel and roller etc.
Application can be carried out by any suitable techniques and liquor rates ranging from about 2.5 to 3.0 square meter per liter, preferably 2.7 square meter per liter with 0.5 mm Dry Film Thickness (DFT).
The film thickness of the anticorrosive coating film formed from the anticorrosive coating composition of the present invention can be set to an appropriate thickness according to the type, application, and the like of the object to be coated, and is usually about 0.5 mm to 1.5 mm in terms of dry film thickness (DFT).
In addition, it is also possible to repeatedly apply the composition to the anticorrosive coating film formed of the anticorrosive coating composition of the present invention a plurality of times to obtain a dry coating film having a desired film thickness.
In another embodiment of the present invention, the anti-corrosive coating composition has surface drying time in 1 to 3 hours; hard drying time in 12 to 20 hours; and full cure time in 5 to 9 days at 25° to 35°C.
The components of the composition are storable, meaning that they can be stored prior to use for several months up to one year or longer without any change in their respective properties to a degree relevant to their use.
For the use of the epoxy resin composition, the components are mixed with one another shortly before or during application.
The components are mixed by means of a suitable method; this mixing may be done continuously or batch wise. Mixing is carried out in particular at ambient temperature, which is typically in the range from 5 to 50° C., preferably 10 to 30° C.

In another embodiment of the present invention, the anti-corrosive coating composition is capable to provide excellent adhesion on adequately prepared surfaces. The coating composition can be cured under damp conditions as well as under high humidity levels. The cured mass exhibits excellent anti-corrosive properties under adverse saline environment.
In another embodiment of the present invention, the anti-corrosive coating composition can also be used at new building, repair or on board maintenance purposes.
With its advantageous properties as regards odor, processability, rapidity of curing, and robustness towards blushing-related defects, the epoxy resin composition of the invention is particularly suitable for any required surface of a ship, boat or any marine structure.
It is important to appreciate that the anti-corrosive coating composition of the present invention is a balanced composition. By being balanced, one is referring to the overall makeup of the composition and particularly the balancing of various component parts of the composition to yield an effective and efficient final coating once applied to any floor. Thus, there is an important relationship between the solids content of the present anti-corrosive coating composition, the thickness of the dried base layer, and the particle size.
The inventive coating can be used in any situation where non-corrosive surfaces and flooring are required and low-coating weight is desired. Examples include floors, outer surfaces in wet environments such as ship decks and steps on water-going vessels including boats, barges and ships, aircraft carrier flight deck etc.
The following examples are provided to more specifically set forth and define the process of the present invention. It is recognized that changes may be made to the specific parameters and ranges disclosed herein and that there may be a number of different ways known in the art to change the disclosed variables. And

whereas it is understood that only the preferred embodiments of these elements are disclosed herein as set forth in the specification. The invention should not be so limited and should be construed in terms of the spirit and scope of the claims that follow.
EXAMPLES
The invention is now being illustrated with working examples, which is intended to illustrate the working of disclosure and not intended to take restrictively to imply any limitations on the scope of the present disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. The invention will now be explained in more detail that illustrates the invention in a non-limiting matter.
Example 1
A typical manufacturing process for preparing anti-corrosive coating composition includes:
1) Preparation of Component (A): In a clean bead mill, add 58% by weight of Bisphenol A-epichlorohydrin epoxy resin, 10% by weight of phenyl glycidyl ether, 0.8% by weight of BYK-9076 and 0.5% by weight of Disparlon 6650. After mixing for 5-10 minutes, add 5.0% by weight of zinc phosphate, 7.5% by weight of rutile titanium dioxide, 0.65% by weight of carbon black and 14.0% by weight of barium sulfate. Disperse for 60 minutes at 6-7 m/s tip speed. After achieving desired dispersion, stabilized with part of epoxy resin and phenyl glycidyl ether. Discharge stabilized mill base in high speed mixture and add 0.3% by weight of hydroxy group-containing dimethylsiloxanes, 1.25% by weight of 2-[[3-(trimethoxysilyl)propoxy] methyl]oxirane and 2.0% by weight of polyvinyl butyral to finish the batch. Mixed for 30 minutes and packed in drum after filtration;

2) Preparation of Component (B): In a reactor, add 90.0% by weight of cashew nutshell oil polymer with formaldehyde and diethylenetriamine, 5.0% by weight of Polyamide-160 and 5.0% by weight of 2,4,6-tris[(N,N-dimethylamino)methyl]phenol followed by proper mixing at 40-50°C temperature. After mixing, packed in drum after filtration.
3) The component (A) and the component (B) are uniformly mixed in a ratio of 1:0.6 by volume and used. Each of the component was thoroughly mixed prior to application onto any required surface of a ship, boat or any marine structure. The components were mixed using low shear (1000 RPM), and when all the components have been added, the speed was increased to 2000-2500 RPM.
Example 2
The procedure of Example 1 was followed with different percentage of ingredients of the component (A) and component (B) as shown in Tables 2a and 2b:
Table 2a: Component (A)

S.N.
1. 2. 3. 4. 5. Ingredient Weight %

Bisphenol A-epichlorohydrin epoxy resin 56.0%

Phenyl glycidyl ether 12.0%

Zinc Phosphate 6.0%

Barium sulfate 15.5%

Rutile Titanium Dioxide 5.5%

S.N.
6.
7.
8.
9.
10.
11. Ingredient Weight %

Carbon black 0.5%

BYK-9076 0.5%

Disparlon 6650 0.3%

Hydroxy group-containing dimethylsiloxanes 0.2%

2-[[3-(Trimethoxysilyl) propoxy] methyl]oxirane 1.0%

Polyvinyl butyral 2.5%
Table 2b: Component (B)

S.N.
1.
2. 3. Ingredient Weight %

Phenalkamine or Cashew nutshell oil polymer with formaldehyde and diethylenetriamine 85.0%

Polyamide-160 8.0%

2,4,6-Tris[(N, N-dimethylamino)methyl]phenol 7.0%
Example 3
The procedure of Example 1 was followed with different percentage of ingredients of the component (A) and component (B) as shown in Tables 3a and 3b:
Table 3a: Component (A)

S.N.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11. Ingredient Weight %

Bisphenol A-epichlorohydrin epoxy resin 61.0%

Phenyl glycidyl ether 8.0%

Zinc Phosphate 4.0%

Barium sulfate 12.0%

Rutile Titanium Dioxide 8.5%

Carbon black 0.8%

BYK-9076 1.0%

Disparlon 6650 0.7%

Hydroxy group-containing dimethylsiloxanes 0.5%

2-[[3-(Trimethoxysilyl) propoxy] methyl]oxirane 2.0%

Polyvinyl butyral 1.5%
Table 3b: Component (B)

S.N.
1.
2. Ingredient Weight %

Phenalkamine or Cashew nutshell oil polymer with formaldehyde and diethylenetriamine 95.0%

Polyamide-160 2.5%

S.N.
3. Ingredient Weight %

2,4,6-Tris[(/V,/V-dimethylamino)methyl]phenol 2.5%
The present invention may, of course, be carried out in other specific ways than those herein set forth without parting from the spirit and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended Claims are intended to be embraced therein.
The numerical values of various parameters given in the specification are at approximations and slightly higher or slightly lower values of these parameters fall within the ambit and the scope of the invention.
While considerable emphasis has been placed herein on the specific steps of the preferred process, it will be highly appreciated that many steps can be made and that many changes can be made in the preferred steps without departing from the principles of the invention. These and other changes in the preferred steps of the invention will be apparent to those skilled in the art from the disclosures herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.
It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
ADVANTAGES OF THE PRESENT INVENTION:

1. The present disclosure provides a solvent-free epoxy anti-corrosive and also an anti-slip paint, which does not contain organic volatile ingredient and offers excellent mechanical properties.
2. Solvent-free paint composition also overcome the risk of fire due to solvent evaporation, solvent loss and other shortcomings.
3. The present disclosure provides a coating composition, which is self-priming single coat application with excellent adhesion to metal, thereby reducing the number of construction, improve work efficiency.
4. The present disclosure provides a coating composition, which is having properties of good heat reflection, weather resistance and excellent anti-corrosive effect.
5. The present disclosure provides a coating composition, which is resistance to saline water, oil, fuels and mild chemicals.
6. The present disclosure provides a coating composition, which is free from surface defects, easy to clean and hygienic.
7. The present disclosure provides a coating composition, which do not prepare pin holes after drying, through which corrosion process can be start.
8. The present disclosure provides a coating composition, which is vibration and environmental corrosion resistance.
9. The present disclosure provides a coating composition, which is having good wear resistance and anti-sticking.
10. The present disclosure provides a coating composition, which is having long-lasting performance, good flexibility and excellent temperature resistance and chemical resistance.

11. The preparation method of the invention is simple, can obviously improve production efficiency, reduce energy consumption, facilitate popularization and application, and the product quality has a solid content close to 100%.

I/We claim:
1. A solvent-free anti-corrosive coating composition comprising component A
and component B, wherein component A comprises:
a) binder having weight concentration in the range of 54-62%;
b) reactive diluent having weight concentration in the range of 8-12%;
c) anti-corrosive pigment having weight concentration in the range of 4-6%;
d) filler having weight concentration in the range of 12-16%; and
e) opacity provider having weight concentration in the range of 5-10%;
and component B comprises:
f) cardanol based curing agent having weight concentration in the range of 85-95%;
g) low viscosity reactive polyamide having weight concentration in the range of 3.0-8.0%; and
h) accelerator having weight concentration in the range of 3.0-8.0%.
2. The composition as claimed in claim 1, wherein the mixing ratio of component A and component B is in the range of 2:1 to 10:7 by volume.
3. The composition as claimed in claim 2, wherein the mixing ratio of component A and component B is 5:3 by volume.

4. The composition as claimed in claim 1, wherein component-A further
comprises at least one ingredient selected from the group consisting of:
a) organic pigment having weight concentration in the range of 0.5-1.0 %;
b) wetting and dispersing additive having weight concentration in the range of 0.5-1.0 %;
c) rheology modifier having weight concentration in the range of 0.30-0.80 %;
d) defoamer having weight concentration in the range of 0.1-0.5 %;
e) adhesion promoter having weight concentration in the range of 1.0-2.0 %; and
f) flexibility additive having weight concentration in the range of 1.5-2.5 %.
5. The composition as claimed in claim 1, wherein said
binder is selected from the group consisting of bisphenol A-epichlorohydrin epoxy resin, bisphenol F-epichlorohydrin epoxy resin, diglycidyl ether of novolac resin, hydrogenated bisphenol A, F or A/F epoxy resin, and combinations thereof;
reactive diluent is selected from the group consisting of glycidyl ethers of phenols, cresols, butanol, alkyl phenols such as phenylglycidyl ether, butylglycidyl ether and the like, and combinations thereof;
anti-corrosive pigment is selected from the group consisting of zinc phosphate, calcium phosphate, calcium magnesium orthophosphate, zinc

aluminum orthophosphate, zinc chromate, zinc molybdate, aluminum molybdate, aluminum tripolyphosphate, magnesium oxyaminophosphate, and combinations thereof;
filler is selected from the group consisting of barium sulfate, silica, alumina, silicates, hydrated magnesium silicate (or talc), hydrated potassium aluminum silicate, kaolin, glass flakes, calcium sulfate, micaceous iron oxide, and combinations thereof; and
opacity provider is selected from the group consisting of rutile titanium dioxide, zinc oxide, and combinations thereof.
6. The composition as claimed in claim 4, wherein said
organic pigment selected from the group consisting of carbon black, white
lead, graphite, zinc sulfide, chromium oxide, yellow nickel titanium, yellow
chromium titanium, yellow iron oxide, red iron oxide, black iron oxide,
phthalocyanine blue, phthalocyanine green, ultramarine blue,
benzimidazolone yellow, quinacridone red, azo red/yellow pigments, and combinations thereof;
wetting and dispersive additive selected from the group consisting of suitable conventional low or high molecular weight polycarboxylic acid, polyacrylate, polyurethane, salt of unsaturated polyamine amide and polyester polymers, and combinations thereof, preferably BYK-9076;
rheology modifier selected from the group consisting of polyamide wax, organo clay, aluminium stearate, hydrogenated castor oil wax, oxidized polyethylene, polyether phosphate, fumed silica, and combinations thereof;

defoamer selected from the group consisting of organo-modified polysiloxane, modified silicone, mineral oil, fluorocarbon, vinyl and acrylic based suitable defoamer, and combinations thereof;
adhesion promoter is selected from the group consisting of bis(trialkoxysilylalkyl)amines, N, N'- bis(trialkoxysilylalkyl)alkylenediamines, gamma-glycidoxypropyl trimethoxy silane, 2-[[3-(trimethoxysilyl) propoxy] methyl]oxirane, N-(2-aminoethyl)-3-aminopropyltrirnethoxysilane, and combinations thereof in combination with at least an organomodified siloxane; and
flexibility additive selected from the group consisting of suitable conventional chlorinated paraffin wax, polyvinyl butyral resin, and combinations thereof.
7. The composition as claimed in claim 1, wherein said
cardanol based curing agent selected from the group consisting of
modified polyamine, phenalkamine, cashew nutshell oil polymer with
formaldehyde and ethylenediamine or diethylenetriamine or
triethylenetetramine or meta-xylenediamine, and combinations thereof;
reactive polyamide selected from the group consisting of reaction product of aliphatic polyamines (diethylenetriamine or triethylenetetramine, tetraethylenepentamine or pentaethylenehexamine) with dimer acids of linoleic and oleic fatty acids; and
accelerator selected from the group consisting of 2,4,6-
tris(dimethylaminomethyl)phenol, triethanolamine (TEA), N,N-
Dimethyldipropylenetriamine, and combinations thereof, preferably 2,4,6-tris(dimethylaminomethyl)phenol.

8. The composition as claimed in any of the preceding claims, further comprising quartz sand of 30-80 mesh size, in an amount ranging from 0.5kg to 1.5kg per liter of said composition for anti-skid feature.
9. The composition as claimed in any of the preceding claims, wherein said composition has surface drying time in the range of 1 to 3 hours; hard drying time in the range of 12 to 20 hours; and full cure time in the range of 5 to 9 days at 25° to 35°C.
10. The composition as claimed in any of the preceding claims, wherein after application and drying, dry film thickness (DFT) is in the range of 0.5mm to1.5 mm.