Traditional anti-corrosion coatings relied heavily on lead compounds and chromates, achieving protection levels of 1000+ hours in salt spray testing. Modern environmental and health regulations have driven the need for alternatives that can match this performance while eliminating toxic components. Current water-based systems must overcome challenges in adhesion strength, cure times, and long-term durability across temperature ranges from -40°C to 150°C.

The fundamental challenge lies in developing water-based formulations that can provide robust barrier protection and active corrosion inhibition without compromising application properties or increasing cure temperatures.

This page brings together solutions from recent research—including silane-modified polyacrylate systems, interpenetrating network primers, zinc-aluminum compositions with nano-additives, and core-shell emulsion technologies. These and other approaches focus on achieving industrial-grade corrosion resistance while meeting modern environmental and safety standards.

1. Water-Based Epoxy-Modified Polyacrylate Coating with Enhanced UV and Chemical Resistance

NANJING CHANGJIANG PAINT CO LTD, 2024

A water-based epoxy-modified polyacrylate coating that provides superior corrosion protection while maintaining excellent performance characteristics. The coating combines a hydrophobic polyacrylate emulsion with a modified epoxy resin system, featuring a proprietary combination of additives that enhance its UV resistance, chemical resistance, and impact durability. The coating exhibits excellent adhesion to multiple substrates, including steel, while maintaining high hardness and gloss retention. Its self-drying mechanism ensures rapid application and curing, with a low pot life and minimal environmental impact.

CN117844328A-patent-drawing

2. Water-Based Polyacrylate Coating with Silane-Modified Resin via Double Pre-Emulsion Seed Polymerization

NANJING CHANGJIANG PAINT CO LTD, 2023

A water-based polyacrylate coating that combines excellent corrosion protection with weather resistance and multiple base materials. The coating achieves superior performance through a unique double pre-emulsion seed emulsion polymerization process, which enables the incorporation of active silane groups into the resin. This process enables the coating to exhibit excellent adhesion, thermal stability, and resistance to both acidic and alkaline environments, while maintaining its water-based formulation. The coating demonstrates superior performance in corrosion protection, weather resistance, and substrate compatibility compared to conventional solvent-based coatings.

CN117247717A-patent-drawing

3. Water-Based Primer with Modified Acrylic Resin and Interpenetrating Network Structure

SHANDONG OCEAN CHEMICAL INDUSTRY SCIENTIFIC RESEARCH INSTITUTE, Shandong Marine Chemical Research Institute, 2023

A water-based primer that combines the benefits of traditional waterborne coatings with enhanced salt spray resistance. The primer comprises a modified acrylic resin, bisphenol A dispersion, formaldehyde amino resin, and anti-rust additives, along with pigments and fillers. The formulation achieves superior salt spray resistance through a molecular interpenetrating network structure formed during curing, while the anti-rust additives prevent rust formation and spread. The primer is environmentally friendly and free of heavy metal fillers, making it suitable for applications in high-salt environments.

4. Water-Based Zinc-Aluminum Paint with Flake Metal Powders and Nano-Titanium Dioxide

SHENYANG UNIVERSITY OF CHEMICAL TECHNOLOGY, 2022

Water-based, non-marking zinc-aluminum paint for thermal insulation and corrosion resistance that replaces traditional Dacromet coatings. The paint comprises flake aluminum and zinc powders, water-based propylene resin, and titanium dioxide nanoparticles. The formulation combines a water-based dispersion with a silane coupling agent and a corrosion inhibitor to achieve enhanced thermal insulation and corrosion protection. The paint's nano-titanium dioxide particles provide superior thermal insulation properties, while the water-based formulation ensures environmental sustainability.

5. Water-Based Zinc-Aluminum Coating with Silane Agent and Self-Curing Mechanism

SHENYANG CHEMICAL UNIV, 2022

Water-based, non-marking zinc-aluminum coatings for automotive and industrial applications that can be cured at low temperatures (300-350°C) while minimizing VOC emissions. The coatings utilize zinc-aluminum powder and a silane coupling agent in a water-based system, with the powder having a diameter range of 5-25 μm and thickness of 0.1-0.5 μm. The powder is cured through a self-contained curing process, eliminating the need for traditional heat-based curing. The formulation enables environmentally friendly, low-temperature curing of zinc-aluminum coatings without compromising performance or safety.

6. Benzene-Free High-Solid Epoxy Paint with Low Molecular Weight and Enhanced Corrosion Resistance

TIANJIN COSCO KANSAI PAINT AND CHEMICALS CO LTD, 2022

Primer-topcoat benzene-free high-solid epoxy high-corrosion-resistant paint that solves the problems of poor appearance state and easy paint defect of common thick coating. The paint has the characteristics of relatively low molecular weight and high solid content, and has less air pollution caused by solvent emission in the spraying and drying processes.

CN114231123A-patent-drawing

7. Epoxy Zinc-Rich Coating with Glass Flakes and Zinc Powder for Enhanced Barrier Properties

WUXI HUADONG ZINDN TECH CO LTD, 2021

Solvent-free epoxy zinc-rich anticorrosive coating with enhanced cathodic protection properties. The coating combines glass flakes and zinc powder to create a tortuous diffusion path in the coating film, effectively delaying corrosion at the substrate interface. The formulation features a high-volume glass flake content, a specific glass flake arrangement, and a proprietary epoxy resin formulation that balances flexibility and barrier performance. This innovative combination enables rapid drying at room temperature while maintaining excellent corrosion resistance and adhesion.

CN112500764A-patent-drawing

8. Corrosion-Resistant Coatings with Dicyclopentadiene-Modified Ester and Urethane Oligomers

PTT GLOBAL CHEMICAL PUBLIC COMPANY LTD, 2020

Corrosion-resistant coatings comprising ester and urethane oligomers with improved performance compared to conventional formulations. The coatings contain dicyclopentadiene modified ester oligomers and dicyclopentadiene modified ester urethane oligomers, which exhibit enhanced corrosion resistance and adhesion properties through oxidative curing. The compositions can be formulated into coatings with improved durability, adhesion, and resistance to environmental stressors.

9. Water-Based Modified Acrylic Coating with Core-Shell and Soap-Free Emulsions for Enhanced Corrosion Resistance

Universal Chemicals Co., Ltd., 海洋化工研究院有限公司, MARINE CHEMICAL RESEARCH INSTITUTE CO LTD, 2020

Water-based modified acrylic anticorrosive coating for container underframes that eliminates the environmental and health risks associated with traditional solvent-based paints. The coating combines a core-shell acrylic emulsion with a soap-free acrylic emulsion, which provides superior workability and corrosion protection. The emulsions are prepared through a controlled polymerization process that incorporates multifunctional additives and flocculants to enhance their performance. The resulting coating exhibits excellent durability, resistance to environmental stressors, and compatibility with various container materials.

10. Water-Based Zinc-Aluminum Coating with Chromium-Free Binder and Silane-Free Coupling Agent System

GUANGDONG INSTITUTE OF ANALYSIS, 广东省测试分析研究所, 2019

A water-based zinc-aluminum anticorrosive coating that replaces traditional chromic anhydride-based coatings with a chromium-free formulation. The coating achieves enhanced corrosion resistance through a silane-free coupling agent system and a novel binder combination that maintains high adhesion properties at elevated temperatures. The coating exhibits superior performance characteristics including low VOC emissions, excellent temperature stability, high color brightness, and excellent salt spray resistance, making it suitable for applications where traditional chromic anhydride-based coatings are restricted.

CN107022300B-patent-drawing

11. Anti-Corrosion Coating Utilizing Modified Polyaspartate Resin with Additive and Pigment Formulation

GUOLIANG XIAO, 2019

Solvent-free, high-performance heavy-duty anti-corrosion coating for industrial equipment featuring enhanced toughness, impact resistance, and environmental sustainability. The coating combines a modified polyaspartate resin with a specific formulation of additives, pigments, and fillers to achieve superior performance in harsh corrosive environments. The coating exhibits excellent resistance to corrosion, salt spray, and aging while maintaining high VOC levels, making it a compelling alternative to traditional epoxy-based coatings.

12. Waterborne Epoxy Primer Composition with Iron Oxide Red and Aluminum Tripolyphosphate Additives

HEBEI CHENYANG IND & TRADE GROUP CO LTD, 2019

Waterborne epoxy primer for marine and industrial applications that replaces traditional solvent-based coatings with a non-toxic, environmentally friendly alternative. The primer combines a waterborne epoxy emulsion with iron oxide red, aluminum tripolyphosphate, and other additives to achieve superior corrosion resistance and durability. The formulation eliminates heavy metals while maintaining excellent performance in corrosive environments.

13. Water-Based Alkyd Enamel Paint with Lead-Free Alkyd Formulation and Water-Based Binder

TIANHENG COATING CO LTD, 2019

Water-based alkyd enamel paint that eliminates lead and improves environmental sustainability. The paint combines a lead-free alkyd formulation with a water-based binder, achieving superior performance characteristics while minimizing environmental impact. The paint's lead-free alkyd formulation replaces traditional lead-based alkyd enamels, providing a safer working environment for workers and protecting the health of the environment.

14. Epoxy Zinc-Rich Primer with Polyamide Resin and 500-Mesh Zinc Powder

CHAMPION PAINT TECH GROUP CO LTD, 2018

Epoxy zinc-rich primer for wear-resistant and anti-corrosion coatings that provides both quick drying and excellent corrosion protection. The primer combines a stable polyamide epoxy resin with a zinc-rich component containing 500-mesh zinc powder, rust-proof pigment, filler, auxiliary agent, and epoxy diluent. The zinc-rich component enhances corrosion resistance while the epoxy resin provides excellent mechanical properties. The primer formulation ensures rapid curing and excellent wear resistance, making it suitable for critical industrial applications such as mine equipment, pipelines, and structural components.

CN108300122A-patent-drawing

15. Water-Based Paint Composition with Advanced Additives and Specialized Fillers

DALIAN BETRUST ENVIRONMENTAL PROTECTION TECHNOLOGY CO., LTD., Dalian Bicheng Environmental Technology Co., Ltd., 2018

Water-based paint and preparation method for achieving improved performance in industrial applications. The paint combines a water-based formulation with advanced additives that address common issues such as poor adhesion, corrosion resistance, and high-temperature stability. The preparation method involves the incorporation of specialized fillers and dispersants that enhance the paint's wetting properties, improve its ability to control adhesion, and enhance its resistance to environmental conditions.

CN105860723B-patent-drawing

16. Water-Based Anti-Corrosion Coating with Acrylic Epoxy Resin and Titanium Blue Pigment

SHENZHEN BAOJUN ENVIRONMENTAL PROTECTION COATING CO., LTD., Shenzhen Baojun Environmental Protection Coatings Co., Ltd., 2018

Water-based environmental protection outer layer anti-corrosion coating and production method. The coating comprises a waterborne acrylic epoxy modified resin, a titanium blue pigment, and a water-based multifunctional pH adjuster. The coating also includes hydropalat 100 dispersant, 0.5-5 parts by weight of Alex F_252 antisepsis mildew fungicide, 1 to 5 parts by weight of PE 100 wetting agent, 5 to 10 part by weight of Hydropalat 3275, 1-5 parts by weight of LS4110 Organic tin driers, water-based paint foam control agent in parts by weight 1-5, water in parts by weight from 10 to 15, water-based multifunctional pH adjuster AMP-95 in parts by weight 0.5-1, parts by weight 5 -10 nano-silica hardener, a strong thixotropic thickener DSX3290 with a weight of 1-5.

17. Paint Composition with Amorphous MgO-V-Based Anticorrosion System for Pre-Coated Steel Sheets

AKTSO NOBEL KOATINGS INTERNESHNL BV, AKZO NOBEL COATINGS INT BV, Akzo Nobel Coatings International B.V., 2017

Chromium-free paint composition for pre-coated steel sheets that achieves superior edge performance through the use of a unique amorphous MgO-V-based compound-based anticorrosion system. The composition comprises a film-forming resin, an aqueous solution of the anticorrosion pigment containing magnesium and vanadium compounds, and a crosslinking agent. The solution has a pH of 10 and contains up to 100 million ppm ions, with a specific ratio of 10-80% by weight of the pigment to the resin and crosslinking agent. This composition provides excellent corrosion resistance at the edges of pre-coated steel sheets, particularly in areas where conventional chromate-based primers are typically used.

18. Waterborne Acrylic Acid-Modified Two-Component Epoxy Primer with Grafted Acrylic Acid Monomer

HEBEI CHENYANG INDUSTRY & TRADE GROUP CO LTD, 2017

Waterborne acrylic acid-modified two-component epoxy primer and process for producing the same, which addresses the limitations of traditional waterborne coatings by combining corrosion protection and weather resistance. The primer comprises an aqueous acrylic acid-modified two-component epoxy system comprising parts A and B in parts by weight, where the acrylic acid monomer is incorporated into the epoxy resin through grafting technology. This hybrid system provides comprehensive performance characteristics, enabling single-coated application for both corrosion protection and weather resistance.

CN106947354A-patent-drawing

19. Waterborne Epoxy Coating with Acrylic Epoxy-Modified Resin and Aluminum Triphosphate

SHENZHEN BAOJUN ENVIRONMENTAL PROTECTION COATING CO LTD, 深圳市宝骏环保涂料有限公司, 2017

A single-component, waterborne epoxy coating that combines excellent corrosion resistance, water resistance, and low-temperature performance. The coating comprises an acrylic epoxy-modified resin, aluminum triphosphate, Hydropal dispersant, antiseptic fungicide, PE100 wetting agent, dispersant, Hydropakat 3275, and thixotropic thickener DSX3290. The coating is formulated to maintain its performance in temperatures as low as -10°C while maintaining excellent water resistance properties.

20. Epoxy Primer with Zinc Phosphate-Based System for Rust Protection

Shanghai Datong Paint Chemical Co., Ltd., SHANGHAI DATONG PAINT AND CHEMICALS CO LTD, 2017

White epoxy primer for rust protection that replaces traditional chromate-based paints by using zinc-free, non-toxic zinc phosphate-based systems. The primer provides superior corrosion resistance while eliminating the environmental hazards associated with traditional chromate-based coatings.

CN103756507B-patent-drawing

21. Waterborne Epoxy-Acrylic Resin Composition with Inorganic Pigments and Additives

22. Waterborne Epoxy Graphene Composite Coating with Enhanced Durability and Corrosion Resistance

23. Architectural Coating Composition with High-Corrosion-Resistant Green Pigmentation

24. Polyester Powder Coating with Specific Component Ratio and Solvent-Free Composition

25. Solvent-Free Preparation Method for Low-VOC Epoxy-Based Composite Coatings with Phenolic Epoxy Amine Curing Agents and Polyurea Topcoat

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