Automotive coatings face increasingly demanding requirements, with field data showing exposure to salt concentrations up to 3% on coastal roads and temperature cycles ranging from -40°C to 90°C in extreme conditions. Traditional coating systems begin showing signs of degradation after 5-7 years, particularly around wheel wells and underbody components where mechanical stress combines with chemical exposure.

The fundamental challenge lies in developing coating systems that maintain barrier properties and active corrosion resistance while meeting strict environmental regulations and automotive production requirements.

This page brings together solutions from recent research—including nanostructured zinc phosphate inhibitors, tertiary amine-based protection systems, synergistic metal polycarboxylate blends, and controlled-kinetics solid-state agents. These and other approaches focus on practical implementation in high-volume automotive manufacturing while meeting increasingly stringent durability requirements.

1. Tertiary Amine-Based Corrosion Inhibitor with Hydroxyethyl Group for Metal Coatings

SHENZHEN FEIYANG JUNYAN NEW MAT CO LTD, 2024

Corrosion inhibitor for metal coatings that prevents paint falling off and extends the corrosion protection period. The inhibitor is a tertiary amine compound with a hydroxyethyl group. It is prepared by reacting an isocyanate with a primary amine and a secondary amine in the presence of water. The reaction forms a tertiary amine with a hydroxyethyl group as an intermediate, which is then used as the corrosion inhibitor. The inhibitor is added to the coating formulation to prevent metal corrosion when the coating is applied.

2. Composite Inhibitory Pigment with Nanostructured Zinc Phosphate on Zeolite Surface Formed by Mechanochemical Synthesis

KARPENKO PHYSICO MECHANICAL INSTITUTE OF THE NAT ACADEMY OF SCIENCES, 2024

Mechanochemical synthesis of a composite inhibitory pigment for corrosion protection of metal structures in corrosive environments. The pigment is formed through a solid-state reaction between synthetic zeolite NaA and zinc dihydrogen phosphate in a planetary ball mill, resulting in the formation of a nanostructured zinc phosphate phase on the zeolite surface. This composite pigment, with a 1:1 zeolite to zinc dihydrogen phosphate ratio, exhibits enhanced solubility in corrosive environments compared to traditional zinc phosphate pigments, while maintaining sufficient inhibitory properties to prevent underfilm corrosion. The composite is then combined with epoxy resin and other additives to create a protective coating system.

3. Corrosion Inhibitor System with Organic Cation Exchange Resins and Phosphate Compounds for Ferrous Metals

HEZIGON INHIBITORS LTD, 2023

Corrosion inhibitors for ferrous metals that combine organic cation exchange resins with phosphate-based compounds. The inhibitors release ions in response to corrosive conditions, while the phosphate compounds form a protective layer. The combination provides enhanced corrosion protection compared to traditional chromate-based systems. The inhibitors can be applied to metal substrates or coatings, and the phosphate-based compounds are environmentally friendly. The system offers improved performance and environmental sustainability over conventional chromate-based coatings.

4. Aqueous Coating Composition with Acrylic Resin Particles and Rust Preventive Agent for Metal Substrates

Kansai Paint Co., Ltd., KANSAI PAINT CO LTD, 2021

Aqueous coating composition for metal substrates that combines excellent corrosion resistance, adhesion, and water resistance. The composition comprises acrylic resin particles with specific requirements for acid value and solubility parameter value, and a rust preventive agent containing aminosilane, azole compound, and fatty acids. The particles have a specific average particle diameter of 50 nm or more, ensuring good dispersion stability, while the rust preventive agent provides enhanced corrosion protection. The composition is suitable for applications requiring high-performance coatings on metal substrates.

CN112384580B-patent-drawing

5. Coating Composition with Film-Forming Resin and Multi-Functional Corrosion Inhibitor Containing Inorganic Metal Compounds and Organic Functional Groups

PPG INDUSTRIES OHIO INC, PPG Industries Ohio Incorporated, 2021

Coating composition containing a corrosion inhibitor that prevents or reduces corrosion of metal substrates, particularly in environments with specific environmental conditions. The composition comprises a film-forming resin and a corrosion inhibitor containing an inorganic alkali metal and/or alkaline earth metal compound, ketone and/or aldehyde groups, and -OR groups. The corrosion inhibitor in the composition comprises an inorganic alkali metal and/or alkaline earth metal compound, ketone and/or aldehyde groups, and -OR groups, which form a compound with aromatic rings having at least one side group represented by each R1 independently selected from hydrogen, an alkyl group, and an aryl group.

KR102330539B1-patent-drawing

6. Solid-State Anti-Corrosion Agent with Controlled Kinetics and Heat Resistance for Vehicle Components

PFINDER KG, 2021

Anti-corrosion agent for protecting vehicle components through controlled kinetics and heat resistance. The agent features a solid state at the end of radiation treatment, eliminating the need for post-processing cleaning and finishing. This agent can be applied to components like engine blocks, transmission mounts, and wheel hubs, providing comprehensive corrosion protection through controlled crosslinking and drying kinetics. The agent's solid state ensures uniform distribution and penetration, while its controlled reaction kinetics enables precise control over the corrosion protection process.

7. Organic Corrosion Inhibitors Comprising Onium Cation Groups and Aromatic Carboxylate Counter-Anions

UNIV DEAKIN, 2021

Organic corrosion inhibitors comprising onium cation groups and aromatic carboxylate counter-anions, which can be used as a corrosion inhibitor for various substrates. The inhibitors form ionic compounds that provide effective corrosion protection through various mechanisms including barrier protection, sacrificial protection, and corrosion inhibition. The inhibitors can be formulated as curable coatings or as a composition containing onium cation groups and aromatic carboxylate counter-anions, which can be used as a corrosion inhibitor for various substrates.

WO2021097532A1-patent-drawing

8. Metal Polycarboxylate Blend with Varying Cations for Corrosion Inhibition

UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY OF THE NAVY, 2020

A synergistic metal polycarboxylate combination for enhanced corrosion protection. The composition comprises a blend of metal polycarboxylates, specifically designed to provide superior corrosion resistance compared to individual compounds. The synergistic blend combines metal salts with varying cations to inhibit galvanic corrosion on metal substrates, particularly effective for multiple metals and accelerated corrosion tests. The composition can be applied to coatings or binders to protect metal surfaces while maintaining adhesion.

US2020283912A1-patent-drawing

9. Coating Composition for Auto Parts with Acrylic Resins, Molybdenum Disulfide, and Zinc Powder

JIANGSU KEYAN AUTO PARTS CO LTD, 2020

A coating for auto parts that provides better corrosion resistance and environmental friendliness compared to traditional solvent-based coatings. The coating contains a specific composition of acrylic resins, thermosetting acrylic resins, 2-methacrylamide, molybdenum disulfide, polytetrafluoroethylene, silica, zinc powder, anti-rust pigments, hardeners, surfactants, leveling agents, and defoamers. The coating aims to replace solvent-based coatings for auto parts like chassis, brackets, and wheels by reducing VOCs, improving corrosion resistance, and avoiding pollution from waste solvents and water treatment.

10. Two-Pack Epoxy Paints with Zinc Salt-Infused Resin and Hardener Formulation

ALLNEX AUSTRIA GMBH, 2020

Two-pack epoxy paints with improved corrosion resistance, particularly for metal substrates like steel, that achieve enhanced protection through the incorporation of zinc salts. The paints contain a zinc salt component that enhances the coating's anti-corrosion properties, while maintaining its impact resistance and weldability. The zinc salts are incorporated during the epoxy resin and hardener formulation, ensuring optimal performance in both corrosion protection and mechanical properties.

11. Anticorrosive Coating Composition with Low T2 Propionate Resin and Nitrocellulose Liquids

SICHUAN HANGTIAN SHIDONG AUTO PARTS CO LTD, 2019

An anticorrosive coating for automotive parts comprising: 15-25 parts by mass of low T2 propionate resin, 2-3 parts by mass of pigments, 10-15 parts by mass of low-heavy metal zinc phosphate, 4-6 parts by mass filler, 0.5-1 parts by mass dispersant, 0.1-0.5 parts by mass defoamer, 35-40 parts by mass 1/2s nitrocellulose liquid, 12-16 parts by mass 30s nitrocellulose liquid, 1-3 parts by mass of functional auxiliary and 2-4 parts by mass of mixed solvent.

CN109810580A-patent-drawing

12. Corrosion-Resistant Metal Coating with Rheological Additive and Non-Toxic Pigment

3M INNOVATIVE PROPERTIES COMPANY, 3M Innovative Properties Company, 2019

A corrosion-resistant, sprayable coating for metal surfaces that inhibits corrosion while maintaining excellent sagging properties. The coating comprises a non-toxic, environmentally friendly pigment with a rheological additive that enhances its anti-sagging performance. The additive improves the coating's flowability and stability across a broad temperature range, enabling effective application on complex metal substrates. The coating exhibits superior corrosion protection properties compared to conventional zinc-based systems while meeting stringent safety and environmental standards.

13. Cation Exchange Pigment-Based Coatings with Anion Blocking for Metal Substrates

ANCATT INC, 2019

Cation exchange pigment-based coatings for protecting metal substrates from corrosion. The coatings contain a cation exchange pigment that prevents anions from passing through the layer, thereby preventing metal oxide formation. The pigment can be incorporated into a topcoat layer, and may be combined with primer layers or interlayers. The coatings can be formulated with various binder materials and additives to achieve desired properties.

US2019136072A1-patent-drawing

14. Automotive Paint Composition with Rust-Inhibiting Emulsion and Mica-Zeolite Additives

CHENGDU SHUNHONGXIN MACHINERY CO LTD, 2018

Anti-corrosion and anti-rust paint for automobiles that addresses the challenges of traditional automotive coatings. The paint combines a rust-inhibiting emulsion with mica powder, driers, zinc oxide, wollastonite powder, polyvinyl chloride resin, zeolite powder, and acrylonitrile to create a durable and long-lasting protective barrier. The formulation balances performance with environmental considerations, providing superior corrosion protection while maintaining paint adhesion and drying characteristics.

CN107746593A-patent-drawing

15. Car Paint Composition with Cobalt Catalyst and Hydroxy Acrylic Resin Incorporating Titanium Dioxide and Short Oil Alkyd

RONGKENG LIANG, 2018

Anti-corrosion car paint with enhanced durability and environmental performance. The paint combines a cobalt catalyst with a hydroxy acrylic resin, driers, and specialized additives to improve corrosion resistance while maintaining aesthetic properties. The formulation incorporates advanced materials like titanium dioxide, short oil alkyd, and organic soil to address environmental concerns. The paint system provides superior corrosion protection, durability, and resistance to environmental degradation.

16. Composite Corrosion Inhibitor with Hydroxyethyl Imidazoline and Acetylene Alcohol Complex

CHEM YUEYANG WATERBORNE ADDITIVE CO LTD, 2017

A composite corrosion inhibitor for metal surfaces that combines the benefits of organic corrosion inhibitors with improved wetting, dispersibility, and adhesion properties. The inhibitor comprises hydroxyethyl imidazoline (30-60%) and acetylene alcohol (3-20%) in a synergistic complex. The imidazoline component enhances film formation properties, while the acetylene alcohol component improves wetting and dispersion characteristics. The inhibitor formulation provides enhanced corrosion protection through both chemical and mechanical mechanisms, enabling effective protection of metal surfaces in aqueous environments.

CN107475722A-patent-drawing

17. Aqueous Coating Composition with Trialkanolamine and Carboxylic Acid Complexing Agents

LUBRIZOL CORP, Lubrizol Corporation, 2017

Aqueous coating composition for metal surfaces that provides both rapid and long-term corrosion protection. The composition comprises a corrosion inhibitor component comprising a first complexing agent containing a trialkanolamine and a second complexing agent comprising a carboxylic acid. The composition is prepared by mixing the complexing agents with water, forming a corrosion inhibitor component, and adding the corrosion inhibitor component to the aqueous coating composition. The resulting coating composition provides early rapid rust protection and long-term corrosion resistance, with improved performance even after drying.

18. Anticorrosive Coating Composition for Plastics Incorporating Bisphenol F Epoxy Resin and Fluorinated Polymer

SUZHOU NIUDONG PREC MFG SCIENCE & TECH CO LTD, 2017

A novel anticorrosive coating for automotive plastics that enhances durability and resistance through a combination of advanced materials. The coating comprises a bisphenol F type liquid epoxy resin, calcium chloride, quartz, butyl acetate, cellulose ether, and a fluorinated polymer. The coating is prepared through a multi-step process involving precise temperature control, precise mixing, and controlled addition of the fluorinated polymer. This results in a transparent, colorless liquid that forms a durable, corrosion-resistant film on plastics.

19. Powder Coating Composition with Corrosion-Resistant Metal Oxide for Automotive Surfaces

JIANGSU CHANGSONG TECHNOLOGY DEVELOPMENT CO LTD, 2017

A durable powder coating for automobiles that prevents corrosion through enhanced surface protection. The coating comprises a powder composition comprising a corrosion-resistant metal oxide, a binder, and a pigment. The metal oxide component provides the primary corrosion protection, while the binder and pigment enhance the powder's durability and color retention. The coating is formulated to maintain its protective properties over time, even in harsh environmental conditions, making it suitable for automotive applications.

20. Anti-Corrosion Coating with Specialized Formulation and Application Technique for Automotive Storage Boxes

ANQING HEHUA CHEMICAL CO LTD, 2016

Anti-corrosion coating and preparation method for automotive storage boxes that enhances durability and protection against environmental degradation. The coating and preparation process involves a specialized anti-corrosion paint formulation and application technique that incorporates advanced materials and technologies to provide superior protection against moisture, humidity, and environmental factors. The coating provides comprehensive corrosion protection, while the preparation method ensures uniform and efficient application. The coating and preparation system is particularly effective for automotive storage boxes, where environmental conditions can be extreme and storage conditions are critical.

CN106046996A-patent-drawing

21. Corrosion-Resistant Coating with Zinc, Chromium, and Molybdenum for Automotive Metal Surfaces

22. Paint Formulation Comprising Polyaniline and Epoxy Resin in Specific Mass Ratio

23. Alkyd Paint with Protein-Modified Resin Incorporating Milk Proteins and Network Structure for Enhanced Rheological Properties

24. Metal Surface Corrosion Inhibitors with Alkoxylated Fatty Phenol and Alcohol Phosphate Esters

25. Automotive Paint Composition with Antistatic Agents, Conductive Carbon Black, and Specialized Polymers

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