Liner based on multilayer elastomer

Abstract

The present disclosure relates to a liner based on a multi-layer elastomer. In at least one embodiment, a coated substrate includes a substrate and a first elastomeric coating disposed on the substrate. The first elastomer coating is substantially sulfur-free and includes a first elastomer selected from the group consisting of polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof. The coated substrate includes a second elastomeric coating layer disposed on the first coating layer. The second elastomer coating includes a second elastomer selected from the group consisting of polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof. The first elastomer is the same as or different from the second elastomer, and at least one of the first elastomer or the second elastomer is a polyurea-polyurethane copolymer.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Patent Application 17 / 947,400, filed on September 19, 2022, which is incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to multi-layer elastomer-based liners. Background Art

[0004] A liner (sheet) is a substrate on which a coating is disposed and is used as a covering for open storage facilities such as lagoons and secondary containment units for oil and gas recovery. Specifically, above-ground oil storage tanks, chemical storage tanks, and similar facilities typically employ a secondary containment system to capture hazardous liquids leaking or spilling from the tanks. Secondary containment is also used for retention ponds, lakes, and similar facilities to prevent contaminants such as drilling water, acids, gases, and other chemicals from entering the groundwater table. Traditional secondary containment systems use impermeable or waterproof liners that extend across the pond or retention area. The liner is designed to prevent oil, chemicals, and other substances from seeping into the ground and typically includes multiple juxtaposed geotextile panels. These panels are cut as required, arranged across the containment area, and then sprayed with a polyurea coating such that the panels are impermeable to liquids discharged from the tank or otherwise retain liquids within the retention facility.

[0005] For lagoons, the coating of the liner has weight, and excessive coating can affect the engineering buoyancy of the liner, i.e., the relationship between the weight of the coated substrate and the buoyancy of the overall liner.

[0006] In addition, pre-sprayed polyurea liners have been provided by directly applying a single-layer polyurea coating to a substrate such as woven or non-woven polypropylene or polyester geotextiles. Such coatings are considered thick (40 - 60 mils), and if desired, a slightly oversprayed polyurea is typically applied to the polyurea top surface to provide texture. However, for specific applications such as drinking water, the cost of different polyurea coatings may be too high. In addition, if an overspray or topcoat is applied on-site or during installation (e.g., at an oil and gas well site), proper surface preparation of the entire substrate surface must be carried out; otherwise, delamination between coatings may occur. Surface preparation can include cleaning with acetone and sanding the surface with a grinding wheel. Proper surface preparation requires a significant amount of work, which increases costs, and in many cases, if the surface preparation is incorrect or insufficient, it can lead to poor quality, including blistering and delamination of the liner coating.

[0007] There is a need to improve the method of manufacturing liners and also to have liners with improved coatings that provide cost - effectiveness in addition to reduced blistering and delamination.

[0008] The references cited in the information disclosure statement include (37 CFR 1.97(h)): US 2015 / 0284924, US2022 / 0073272, US 2014 / 0353310, US 7,922,423. Summary of the Invention

[0009] The present disclosure generally relates to multi - layer elastomer - based liners.

[0010] In at least one embodiment, the coated substrate includes a substrate and a first elastomeric coating disposed on the substrate. The first elastomeric coating includes a first elastomer selected from the group consisting of polyureas, polyurethanes, polyurea - polyurethane copolymers, and combinations thereof. The coated substrate includes a second elastomeric coating disposed on the first coating. The second elastomeric coating is substantially sulfur - free and includes a second elastomer selected from the group consisting of polyureas, polyurethanes, polyurea - polyurethane copolymers, and combinations thereof. The first elastomer is the same as or different from the second elastomer, and at least one of the first elastomer or the second elastomer is a polyurea - polyurethane copolymer.

[0011] In at least one embodiment, a method of manufacturing a coated substrate includes: applying a first liquid elastomer to a substrate at a first fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit to form a first elastomeric coating. The method includes: during the set time of the first elastomeric coating, applying a second liquid elastomer to the first elastomeric coating at a second fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit to form a second elastomeric coating disposed on the first elastomeric coating. The second elastomeric coating is substantially sulfur - free. The second fluid temperature is the same as or different from the first fluid temperature. Brief Description of the Drawings

[0012] To enable a detailed understanding of the above - described features of the present disclosure, the present disclosure briefly summarized above can be described in more specific terms with reference to the aspects shown in the drawings. However, it is noted that the drawings only show typical aspects of the present disclosure and should not be considered as limiting its scope, as the present disclosure can admit other equally effective aspects.

[0013] Figure 1 is a cross - sectional side view of a liner according to an embodiment.

[0014] Figure 2 is a secondary protection unit according to an embodiment.

[0015] For ease of understanding, where possible, the same reference numbers are used to denote the same elements common to the figures. The figures are not drawn to scale and may be simplified for clarity. It is contemplated that elements and features of one aspect may be beneficially incorporated into other aspects without further elaboration. Detailed Description

[0016] The present disclosure generally relates to multi-layer elastomer-based linings. More specifically, the present disclosure provides improved methods for manufacturing linings, as well as a need for linings with improved coatings that provide cost benefits in addition to reduced blistering and delamination. In some embodiments, a primary (elastomeric) coating is applied to a substrate at an initial coating thickness (e.g., 20 - 50 mils), and then a secondary spray topcoat is applied within the recoat window of the primary coating (e.g., before the primary coating gels and / or becomes tack-free), thereby providing various benefits such as reducing the overall cost of the resulting lining in addition to alleviating quality issues of traditional linings associated with poor or inadequate pretreatment (e.g., blistering and delamination). The methods of the present disclosure can also alleviate or even eliminate the labor-intensive surface pretreatment of the substrate prior to coating, making such surface pretreatment merely optional because: (1) when a pre-sprayed lining is used as an overcoat, the underlying surface such as concrete or steel need not be pretreated and directly coated; (2) if there is an already coated lining and a topcoat is desired to be added in accordance with the recoat window of the first coating, then the entire surface must be pretreated prior to applying the second coating.

[0017] In some embodiments, for applications where the lining is desired to have a textured or slip-resistant feature, an abrasive medium is applied to the surface of the primary coating within the recoat window of the primary coating (e.g., during the gelation window and / or the tack-free window) after the primary coating is applied and before the secondary coating is applied. This allows the medium to be embedded into the primary coating, and the application of the secondary coating "locks" the medium to form the desired textured or slip-resistant surface. This method can save additional costs because the abrasive medium can only be used on the surface of the primary coating (as opposed to being dispersed throughout the primary coating, which would weaken the strength of the primary coating). This method also reduces or eliminates the loss of the abrasive medium over time compared to a lining where the abrasive medium is applied to the primary coating and there is no secondary coating.

[0018] The linings of the present disclosure can provide high-quality, low-cost solutions for applications that meet high-performance characteristics such as NSF61 potable water, UV color stability, NFSIB101.3 - 2022 DCOF (Dynamic Coefficient of Friction) high abrasion resistance or chemical resistance applications. Accordingly, the topcoat system is NSF61 certified, aliphatic, and / or has high abrasion resistance.

[0019] In at least one embodiment, the coated substrate includes a substrate and a first elastomeric coating disposed on the substrate. The first elastomeric coating includes a first elastomer selected from the group consisting of: polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof. The coated substrate includes a second elastomeric coating disposed on the first coating. The second elastomeric coating includes a second elastomer selected from the group consisting of: polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof. The first elastomer is the same as or different from the second elastomer, and at least one of the first elastomer or the second elastomer is a polyurea-polyurethane copolymer.

[0020] In at least one embodiment, a method of manufacturing a coated substrate includes: applying a first liquid elastomer to the substrate at a first fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit to form a first elastomeric coating. The method includes: during the cure time of the first elastomeric coating, applying a second liquid elastomer to the first elastomeric coating at a second fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit to form a second elastomeric coating disposed on the first elastomeric coating. The second fluid temperature is the same as or different from the first fluid temperature.

[0021] Lining

[0022] The lining of the present disclosure may include a substrate, a first coating, an abrasive disposed on the first coating, and a second coating disposed on the first coating and the abrasive.

[0023] Figure 1 is a cross-sectional side view of the lining 100 of the present disclosure. As Figure 1 shown, the lining 100 has a substrate 102. A first coating 104 is disposed on the substrate 102. A plurality of abrasives 106 are disposed at a surface 108 of the first coating 104. A second coating 110 is disposed on the plurality of abrasives 106 and the surface 108 of the first coating 104. In some embodiments (not shown), the abrasives are additionally or alternatively disposed on the second coating 110. The lining 100 further includes a plurality of protrusions 112 at a surface 114 of the second coating 110. The plurality of protrusions 112 provide texture (e.g., a slip-resistant surface) at the surface 114 of the second coating 110 and are formed due to the presence of the plurality of abrasives 106 (e.g., a plurality of abrasive particles) at the surface 108 of the first coating 104. In some embodiments, the lining of the present disclosure has a traction level of about 0.42 or higher, such as about 0.43 to about 0.6, such as about 0.45 to about 0.5, as evaluated by NSF I B101.3 - 2020 DCOF flooring.

[0024] In some embodiments, the first coating 104 has a thickness (t1) of from about 5 mils to about 100 mils, from about 5 mils to about 60 mils, such as from about 25 mils to about 40 mils, such as from about 30 mils to about 35 mils. The second coating 110 has a thickness (t2) of from about 5 mils to about 40 mils, such as from about 5 mils to about 30 mils, such as from about 10 mils to about 20 mils or from about 5 mils to about 10 mils. The first coating 104 and the second coating 110 together can have a total thickness (t 总 ) that is thinner than that of a conventional single-layer coated liner, which provides a reduced total weight of the liner of the present disclosure and increases the overall buoyancy of the liner. In some embodiments, the total thickness (t 总 ) of the first coating 104 and the second coating 110 is from about 40 mils to about 90 mils, or about 60 mils or less, such as from about 10 mils to about 60 mils, such as from about 10 mils to about 50 mils, such as from about 20 mils to about 40 mils.

[0025] In some embodiments, an additional elastomeric coating is provided as part of the coated substrate. For example, after the first coating 104 and the second coating 110 are applied to the substrate 102, the liner can be flipped to expose the remaining surface area of the substrate 102. Then, a third elastomeric coating (not shown) is applied to the substrate 102, which can be the same as or similar to the first coating 104. Then, (e.g., during the recoat window of the third elastomeric coating), a fourth elastomeric coating (not shown), which can be the same as or similar to the second coating 110, is applied to the third elastomeric coating. By way of example, the substrate 102 can be encapsulated with one or more elastomeric coatings, which renders the coated substrate substantially impervious to water. The coatings can also prevent or eliminate, or at least mitigate, the hygroscopicity of the substrate. The coatings can also protect the substrate from damage during storage, transportation, and installation handling.

[0026] Substrate

[0027] The substrate of the present disclosure can be any suitable substrate.

[0028] In some embodiments, the substrate comprises a flexible geotextile sheet formed of an industrial fabric made of woven fibers. The geotextile can be made of polypropylene or polyester fibers. The geotextile can provide reinforcement in the ground while allowing drainage or filtration, for example, to control erosion.

[0029] The sheet is a substrate to which a liquid elastomeric coating that is impermeable to liquids is applied by spraying or otherwise.

[0030] In some embodiments, the substrate can be made of or include the following materials: polyurethane (e.g., expanded polyurethane), concrete, metal, wood, paper, fiberglass, fiberboard, gravel, or combinations thereof. The substrate can be made of or include the following materials: open-cell foam or closed-cell foam. Open-cell foam has an open cell structure that allows moisture or vapor to pass through, while closed-cell foam has a closed cell structure that can prevent moisture or vapor from passing through due to the sealed cells. Due to this difference, open-cell foam tends to be softer when compressed, while closed-cell foam tends to be harder when compressed. The foam can be polystyrene (e.g., expanded polystyrene), polyisocyanurate, polyurethane, polyvinyl chloride, polyimide, silicone, or combinations thereof. The foam utilized can have any suitable density. For example, the density of the foam can be from about 0.5 pounds per cubic foot (lb / ft 3 ) to about 8 lb / ft 3 or higher, such as from about 1 lb / ft 3 to about 5 lb / ft 3 , such as from about 1.5 lb / ft 3 to about 3 lb / ft 3 , such as from about 2 lb / ft 3 to about 2.5 lb / ft 3 . In one or more exemplary embodiments, the foam has a density of from about 1.5 lb / ft 3 to about 2.5 lb / ft 3 .

[0031] The substrate can be a cloth, such as a woven cloth or a non-woven cloth, or include a non-woven cloth and a non-woven cloth. The cloth can be a geotextile, such as a spunbond geotextile or a non-woven geotextile. The spunbond cloth can be provided by Remay under the trade name Typar. The non-woven cloth can be provided by Amoco Geotextiles under the trade name Petromat.

[0032] Two or more layers of the substrate (e.g., two pieces of cloth) can be used as a single substrate (e.g., substrate 102). Air can be trapped between the two layers of the substrate, thereby providing buoyancy to the entire lining.

[0033] The dimensions (e.g., length and width) of the substrate can be provided according to the desired end use of the lining. For example, if used as a secondary containment unit or a lagoon lining, the substrate can have a width of from about 5 feet to about 20 feet, such as from about 8 feet to about 16 feet, such as about 12 feet, and / or a length of from about 20 feet to about 120 feet, such as from about 30 feet to about 80 feet, such as from about 50 feet to about 70 feet.

[0034] The substrate may be in the form of a web having a desired width, whereby the web is partially unwound and cut with a cutting machine or tool to produce a substrate having a desired length.

[0035] Abrasive

[0036] The abrasive may be sand, cinder, alumina, rubber particles, ceramic beads, glass beads, or a combination thereof. The abrasive may have any suitable shape, such as spherical, rectangular, etc. In some embodiments, the abrasive is substantially spherical and / or has an average particle size of about 0.5 mm to about 1.5 mm, such as about 0.75 mm to about 1.25 mm.

[0037] The abrasive may cover any suitable percentage of the top surface of the first coating (e.g., surface 108). For example, the abrasive may be applied at about 0.1 oz / ft 2 to about 1 oz / ft 2 such as 0.2 oz / ft 2 to about 0.6 oz / ft 2 to cover the surface area of the first coating.

[0038] First coating and second coating

[0039] The first coating may provide adhesion to the substrate, as well as to the second coating and the abrasive. The second coating may provide adhesion to the first coating and the abrasive in a manner that reduces or eliminates blistering and delamination between the coating and the substrate, and between the coatings. In addition, the second coating may provide aliphatic qualities (such as UV properties (reduced or eliminated UV absorption compared to aromatic), and hydrophobicity), potable water qualities (such as non-toxic and biodegradable), and mechanical properties (such as abrasion resistance, tear resistance, puncture resistance, etc.). In some embodiments, the first coating may be an aromatic coating (e.g., having a high aromatic content), while the second coating may be an aliphatic coating (e.g., having a high aliphatic content).

[0040] In some embodiments, the second coating is substantially sulfur-free. For example, the second coating has a sulfur content of about 1 wt% or less, such as about 0.5 wt% or less, such as about 0.01 wt% to about 0.4 wt%, or about 0 wt%. In some embodiments, the sulfur content is determined based on sulfur dioxide content and / or polysulfides.

[0041] The first coating and the second coating may independently be any suitable elastomeric coating. The elastomer may include polyureas, polyurethanes, polyurea-polyurethane copolymers, or a combination thereof.

[0042] Polyureas are commercially available, such as polyureas available from Sherwin Williams under the name ENVIRO PLASTICTM AR200HD or polyureas available from Versaflex under the name FSS 50DM. The polyureas can be applied in Part A (isocyanate) and Part B (polyamine). The polyureas can have a Shore D hardness of from about 40D to about 65D, such as from about 50D to about 60D, according to ASTM D2240. The polyureas can have a tear strength of from about 400 pounds per linear inch (PLI) to about 600 PLI, such as from about 470 PLI to about 500 PLI, according to ASTM D624. The polyureas can have a tensile elongation of from about 100% to about 300%, such as from about 200% to about 250%, such as from about 180% to about 220%, according to ASTM D638. The polyureas can have a tensile modulus (100%) of from about 1000 psi to about 1500 psi, such as from about 1200 psi to about 1300 psi, according to ASTM D638. The polyureas can have a tensile modulus (300%) of from about 2500 psi to about 4000 psi, such as from about 2800 psi to about 3200 psi, according to ASTM D638. The polyureas can have a cure time of from about 1 second to about 30 seconds, such as from about 3 seconds to about 7 seconds, according to ASTM D1640.

[0043] The polyurea / polyurethane copolymer can be any suitable copolymer, such as a polyurea: polyurethane copolymer in a volume ratio of 1:1. Polyurea-polyurethane is commercially available, such as the polyurea-polyurethane copolymers named FREEDOMTUFFTM 1570 or FREEDOMTUFFTM 1595 available from Freedom Chemical Corp., both of which are ultraviolet-stable polymers. In some embodiments, the polyurea-polyurethane copolymer has a hardness (Shore D) of about 40D to about 80D, such as about 55D to about 65D, according to ASTM D-2240. In some embodiments, the polyurea-polyurethane copolymer has a tear resistance of about 400 PLI to about 800 PLI, such as about 400 PLI to about 500 PLI or about 600 PLI to about 700 PLI, both according to ASTM D-624. In some embodiments, the polyurea-polyurethane copolymer has a tensile strength of about 2000 PSI to about 4000 PSI, such as about 2300 PSI to about 2500 PSI or about 2900 PSI to about 3100 PSI, according to ASTM D-412. In some embodiments, the polyurea-polyurethane copolymer has an elongation at break of about 500% to about 750%, such as about 500% to about 600% or about 600% to about 650%, according to ASTM D-412. In some embodiments, the polyurea-polyurethane copolymer has a setting time of about 5 seconds to about 40 seconds, such as about 12 seconds to about 25 seconds, or about 9 seconds to about 12 seconds, at 66 °C when formed (e.g., the reactant coating).

[0044] The presence of the first elastomeric coating and the second elastomeric coating can also be used for wear detection of the linings of the present disclosure. For example, the first elastomer of the first elastomeric coating can have a different color from the second elastomer of the second elastomeric coating. Thus, if the second elastomeric coating starts to wear over time, the first elastomeric coating may start to be exposed to the surrounding environment, and the color of the first elastomeric coating can be visually seen.

[0045] Method for making the lining

[0046] The primary coating can be applied to the substrate manually or by a robot. The secondary coating can be applied to the primary coating and / or the abrasive medium manually or by a robot. The abrasive medium can be applied to the primary coating manually or by a robot.

[0047] The primary coating can be applied to the substrate in an environmentally controlled indoor environment before being transported to the use site, or the primary coating can be applied to the substrate at the use site. The secondary coating and / or abrasive medium can be applied to the primary coating in an environmentally controlled indoor environment before being transported to the use site, or the secondary coating can be applied to the primary coating at the use site. The environmentally controlled indoor environment can be a factory, warehouse, or other manufacturing facility.

[0048] The coatings and abrasive medium can be applied to the substrate and / or each other by any suitable method. The primary coating and / or secondary coating can be applied by spraying monomers, for example, using an applicator hose and nozzle (spraying onto the substrate or primary coating respectively). A pump can supply the monomers from one or more monomer sources through the applicator hose and through the nozzle to the substrate or primary coating. The nozzle can include an impact block for mixing the monomers of the elastomeric coating (e.g., isocyanate monomers, polyamine monomers, and / or polyol monomers). The spraying of the monomers can be carried out by spraying the monomers onto the substrate or primary coating in a reciprocating manner across the substrate to form the first coating or the second coating. The nozzle can spray the liquid monomers at a flow rate of about 1 gallon per minute (gpm) to about 5 gpm, such as about 2 gpm to about 4 gpm.

[0049] The spraying of the monomers can be carried out at a fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit, such as about 140 degrees Fahrenheit to about 180 degrees Fahrenheit, such as about 160 degrees Fahrenheit to about 170 degrees Fahrenheit. The spraying can be carried out at a spraying pressure of about 1000 pounds per square inch to about 2500 pounds per square inch, such as about 1500 pounds per square inch to about 2000 pounds per square inch, such as about 1750 pounds per square inch to about 1850 pounds per square inch.

[0050] In one embodiment where the elastomer is a polyurea-polyurethane copolymer, the polyurea-polyurethane copolymer can be applied in parts A and B using a multi-component, high-pressure 1:1 spraying device. Before application, parts A and B can be preconditioned to about 24 °C to about 27 °C. The spraying can be carried out at a spraying pressure of about 2000 pounds per square inch to about 4000 pounds per square inch, such as about 2500 pounds per square inch to about 3500 pounds per square inch, such as about 2800 pounds per square inch to about 3000 pounds per square inch, and / or at a fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit, such as about 140 degrees Fahrenheit to about 180 degrees Fahrenheit, such as about 160 degrees Fahrenheit to about 170 degrees Fahrenheit.

[0051] The abrasive medium can be applied to the primary coating by spraying, for example, the dry form or the abrasive medium in the presence of a diluent, using an applicator hose and nozzle. The abrasive medium can be applied within the gel window and / or tack-free window of the first coating. For example, in some embodiments, the gel window is from about 30 seconds to about 2 minutes and / or the tack-free window can be from about 2 minutes to about 5 minutes. A pump can supply the abrasive medium from an abrasive medium source through the applicator hose and through the nozzle to the primary coating. The spraying of the abrasive medium can be carried out by spraying the abrasive medium onto the primary coating in a reciprocating manner across the substrate to form a first coating coated with the abrasive medium. The nozzle can spray the abrasive medium at a flow rate of from about 1 pound per minute to about 10 pounds per minute (e.g., from about 2 pounds per minute to about 5 pounds per minute). The nozzle can spray the abrasive medium at a pressure of from about 5 psi to about 25 psi (e.g., from about 10 psi to about 15 psi).

[0052] Additionally or alternatively, when the first coating is conveyed by a conveyor belt located below the hopper, the abrasive medium can be applied to the first coating gravimetrically through the hopper. The hopper can be from about 2 inches to about 10 feet from the surface of the first coating.

[0053] In some embodiments, the abrasive medium and / or the second coating are applied within a recoat window of from about 1 second to about 2 hours, such as from about 30 seconds to about 1 hour, from about 5 minutes to about 1 hour, from about 10 minutes to about 30 minutes, after applying the first coating. In some embodiments, each of the abrasive medium and the second coating is applied within the gel window and / or the tack-free window (before curing) of the first coating. The gel window and / or the tack-free window can also be collectively referred to as the set time of the coating. For example, the abrasive medium and / or the second coating are applied within from about 1 second to about 5 minutes, such as from about 1 second to about 1 minute, from about 3 seconds to about 1 minute, from about 5 seconds to about 30 seconds, after applying the first coating. Applying each of the abrasive medium and the second coating within the gel window and / or the tack-free window (before curing) of the first coating allows the abrasive medium to be locked into the entire lining coating, and the second coating adheres substantially to the first coating, which provides mechanical properties to the lining in addition to providing slip resistance to the lining, and also provides improved delamination and blistering for the lining. The tack-free window (set time) of typical commercial elastomeric coatings is usually very fast to prevent significant sagging and / or other warping of the final coating.

[0054] Optionally, one or more edges of the substrate may remain uncoated or only partially coated. For example, the uncoated edge may be left around the perimeter of the substrate or only along one side or other edge segment of the substrate. When the substrate is assembled and installed at the end-use site, the uncoated edge segment facilitates adhesion of the substrate to an overlapping adjacent piece. Alternatively, the substrate is fully coated with the coating of the present disclosure, and one or more perforations (e.g., annular holes) are formed in the coated substrate to provide areas at the end-use site for tying with one or more straps, hooking with one or more hooks, bolting with one or more bolts, or otherwise connecting the coated substrate (liner) to another structure (e.g., another coated substrate or edge portion of a lagoon or secondary containment unit). Additionally or alternatively, all or part of the coated substrate (liner) is adhered to another structure (e.g., another coated substrate or edge portion of a lagoon or secondary containment unit) using any suitable adhesive. The adhesive may include double-sided tape, glue, thermosetting resin (such as epoxy resin), or a combination thereof. At the end-use site, once tied, adhered, bolted, or otherwise connected to another structure, the portion of the coated substrate that is tied, adhered, bolted, or otherwise connected may be further coated with additional elastomer (e.g., along the seams). Thus, compared to spraying most or all of the entire liner at the end-use site, the liner of the present disclosure provides much less application of elastomer coating at the end-use site. Since much less coating is applied on-site, there is also much less waste of the material forming the coating, fewer storage tanks, and much less applicator equipment transported to the end-use site.

[0055] Final use

[0056] The coated substrate (e.g., liner) of the present disclosure can be used for any suitable end-use. The coated substrate retains its flexibility and is easy to roll up, thus being compact and convenient to transport to the desired end-use site.

[0057] The liner of the present disclosure can be used to cover at least a portion of a fluid or liquid storage area. For example, the liner described herein can be used as a surface cover (e.g., covering the water surface) of a reservoir (such as a wastewater treatment facility, a drinking water storage tank, a recreational lagoon, a swimming pool, a water park, a surfing park, etc.). In addition to preventing substances from entering the reservoir and causing unwanted pollution, the liner can also reduce or prevent evaporation of water or other liquids in the reservoir.

[0058] The lining of the present disclosure can be used as a secondary protective lining. When used as the lining of a secondary protection unit, if there is an accidental fluid leak, overfilling, or spill, the lining will capture the leaked fluid and retain the fluid within the walls of the secondary protection unit, while the lining serves as the bottom of the secondary protection unit. The lining and walls of the secondary protection unit prevent the fluid from seeping into the ground and the groundwater level.

[0059] In some embodiments, the method of the present disclosure includes forming a secondary protection area for an above-ground storage tank. The method includes leveling the site, laying a foundation cushion (e.g., dirt or gravel), constructing a barrier around the site, and covering the foundation cushion and the barrier with the liner of the present disclosure.

[0060] In some embodiments, as Figure 2 shown, the system is generally denoted by reference numeral 210 and includes a modular secondary protection unit 212 that includes a liner 214 extending along the ground. A tank base 216 is located on the liner 214. An above-ground fluid storage tank 218 is located on and supported by the tank base 216. The secondary protection unit 212 surrounds the storage tank 218. In some embodiments, the overall dimensions of the secondary protection unit 212 are 40 feet by 60 feet. In some embodiments, the secondary protection unit 212 has a square or rectangular footprint and ranges in length from about 10 feet to about 100 feet and in width from about 10 feet to about 100 feet.

[0061] In some embodiments, the liner 214 includes a cloth with an elastomeric coating on at least one side, and the tank base 216 engages the side with the elastomeric coating. In some embodiments, the liner 214 includes a cloth and a sprayed-on polyurea coating. In some embodiments, the liner 214 includes a geotextile, a blown fabric, a felt, or other types of cloth with a certain permeability such that the elastomeric coating adheres well to the cloth and forms a solid impermeable layer. In some embodiments, the tank base 216 includes one or more polystyrene pieces, each of which is encapsulated with an elastomer.

[0062] In some embodiments, the system 210 is located at an oilfield production site. The storage tank 218 is suitable for storing fluids such as, for example, water used in hydraulic fracturing operations, or oil, gas, or produced water flowing from a completed oil and gas well. If the storage tank 218 leaks fluid 219 and / or malfunctions, the secondary protection unit 212 will contain the leaked fluid 219 therein.

[0063] As Figure 2As shown, the secondary containment unit 212 includes corner assemblies 220, 222, 224, and 226, and wall assemblies 228, 230, 232, 234, 236, 238, 240, and 242, all of which are connected together. Wall assembly 228 extends from corner assembly 220, and wall assembly 230 extends from wall assembly 228 to corner assembly 222. Wall assembly 232 extends from corner assembly 222, and wall assembly 234 extends from wall assembly 232 to corner assembly 224. Wall assembly 236 extends from corner assembly 224, and wall assembly 238 extends from wall assembly 236 to corner assembly 226. Wall assembly 240 extends from corner assembly 226, and wall assembly 242 extends from wall assembly 240 to corner assembly 220. Liner 214 is connected to each of corner assemblies 220, 222, 224, and 226 and wall assemblies 228, 230, 232, 234, 236, 238, 240, and 242 and extends across the floor area 244 defined thereby.

[0064] In operation, in an exemplary embodiment, if the aboveground fluid storage tank 218 leaks fluid or malfunctions (such as a malfunction caused by corrosion), the secondary containment unit 212 will contain the fluid leaking or flowing out of the storage tank 218, thereby protecting the surrounding environment. Liner 214, corner assemblies 220, 222, 224, and 226, and wall assemblies 228, 230, 232, 234, 236, 238, 240 contain the leaking or flowing fluid and prevent the fluid from flowing into the surrounding environment. Liner 214 prevents the contained fluid from seeping into the ground.

[0065] Other aspects

[0066] Among other aspects, the present disclosure provides the following aspects, each of which may be considered optionally to include any alternative aspect.

[0067] Aspect 1. A coated substrate, comprising:

[0068] A substrate;

[0069] A first elastomeric coating disposed on the substrate, the first elastomeric coating comprising a first elastomer selected from the group consisting of: polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof; and

[0070] A second elastomeric coating disposed on the first elastomeric coating, the second elastomeric coating being substantially sulfur-free and comprising a second elastomer selected from the group consisting of: polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof, wherein the first elastomer is the same as or different from the second elastomer, and at least one of the first elastomer or the second elastomer is a polyurea-polyurethane copolymer.

[0071] Article 2. The coated substrate according to Article 1 further includes a plurality of abrasives disposed between a first surface of the first elastomeric coating and a first surface of the second elastomeric coating, wherein the second elastomeric coating has a plurality of protrusions at a second surface of the second elastomeric coating opposite to the first surface of the second elastomeric coating.

[0072] Article 3. The coated substrate according to Article 1 or 2, wherein the thickness of the first elastomeric coating is about 20 mils to about 100 mils.

[0073] Article 4. The coated substrate according to any one of Articles 1 - 3, wherein the thickness of the second elastomeric coating is about 15 mils to about 40 mils.

[0074] Article 5. The coated substrate according to any one of Articles 1 to 4, wherein the total thickness of the first elastomeric coating and the second elastomeric coating is about 40 mils to about 200 mils.

[0075] Article 6. The coated substrate according to any one of Articles 1 to 5, wherein the substrate includes a geotextile sheet containing a woven fabric or a non - woven fabric.

[0076] Article 7. The coated substrate according to any one of Articles 1 to 6, wherein the substrate includes a foam having a density of about 1 lb / ft 3 to about 3 lb / ft 3 .

[0077] Article 8. The coated substrate according to any one of Articles 1 to 7, wherein the abrasives of the plurality of abrasives are selected from the group consisting of sand, cinder, alumina, rubber particles, ceramic beads, glass beads, and combinations thereof.

[0078] Article 9. The coated substrate according to any one of Articles 1 to 8, wherein the abrasives of the plurality of abrasives are substantially spherical and have an average particle size of about 0.5 mm to about 1.5 mm.

[0079] Article 10. The coated substrate according to any one of Articles 1 to 9, wherein the first surface of the first elastomeric coating has a percentage covered by the plurality of abrasives of about 0.1 oz / ft 2 to about 1 oz / ft 2 .

[0080] Article 11. The coated substrate according to any one of Articles 1 to 10, wherein the second elastomer is a polyurea - polyurethane copolymer.

[0081] Article 12. The coated substrate according to any one of Articles 1 to 11, wherein the second elastomer has:

[0082] Hardness (Shore D) of from about 55D to about 65D as measured according to ASTM D-2240,

[0083] tear strength of from about 400 PLI to about 800 PLI as measured according to ASTM D-624,

[0084] tensile strength of from about 2000 PSI to about 4000 PSI as measured according to ASTM D-412, and

[0085] elongation of from about 500% to about 750% as measured according to ASTM D-412.

[0086] Article 13 A coated substrate according to any one of Articles 1 to 12, wherein each of the first elastomer and the second elastomer is a polyurea-polyurethane copolymer.

[0087] Article 14 A body of water, comprising:

[0088] a liquid storage area; and

[0089] a coated substrate according to any one of Articles 1 to 13 disposed on the liquid storage area.

[0090] Article 15 A method, comprising:

[0091] constructing a barrier around a site including a leveled subgrade pad; and

[0092] covering the subgrade pad with a coated substrate according to any one of Articles 1 to 13.

[0093] Article 16 A method of manufacturing a coated substrate, the method comprising:

[0094] applying a first liquid elastomer to a substrate at a first fluid temperature of from about 100 degrees Fahrenheit to about 200 degrees Fahrenheit to form a first elastomer coating; and

[0095] applying a second liquid elastomer to the first elastomer coating at a second fluid temperature of from about 100 degrees Fahrenheit to about 200 degrees Fahrenheit during a time period of from about 5 seconds to about 5 minutes after forming the first elastomer coating to form a second elastomer coating disposed on the first elastomer coating, the second elastomer coating being substantially sulfur-free, wherein the second fluid temperature is the same as or different from the first fluid temperature.

[0096] Article 17. The method according to Article 16, wherein the first elastomeric coating comprises a first elastomer and the second elastomeric coating comprises a second elastomer the same as or different from the first elastomer, and wherein each of the first elastomer and the second elastomer is independently selected from the group consisting of polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof.

[0097] Article 18. The method according to any one of Articles 15 to 17, wherein the time is from about 5 seconds to about 30 seconds.

[0098] Article 19. The method according to any one of Articles 15 to 18, wherein the time is from about 30 seconds to about 2 minutes.

[0099] Article 20. The method according to any one of Articles 15 to 19, further comprising applying a plurality of abrasives to the first elastomeric coating during the setting time of the first elastomeric coating.

[0100] Article 21. The method according to any one of Articles 15 to 20, wherein the second elastomer is a polyurea-polyurethane copolymer.

[0101] Generally, the multi-layer elastomer-based lining and the method of manufacturing the lining provide an improved coating that provides cost-effectiveness in addition to reducing blistering and delamination of the coating of the lining from the substrate and / or other coatings. The method of the present disclosure can also eliminate or at least mitigate the labor-intensive surface pretreatment of the substrate before coating, making such surface pretreatment unnecessary. For example, overlapping can eliminate direct spraying failures due to insufficient surface pretreatment and / or surface contaminants. The lining and method of the present disclosure enable abrasive media to be embedded in the primary coating (first coating) of the lining, followed by a secondary coating (second coating), which "locks" the media to form the desired texture or anti-slip surface. This method can provide additional cost savings because the abrasive media can be primarily or specifically applied to the surface of the primary coating (rather than being dispersed throughout the primary coating, which would weaken the mechanical properties of the primary coating in this case). This method also reduces or eliminates the loss of abrasive media over time compared to a lining where the abrasive media is applied to the primary coating and there is no secondary coating.

[0102] The lining of the present disclosure can provide a high-quality, low-cost solution for applications that meet high-performance characteristics such as NSF61 potable water, UV color stability, or high wear of NFSIB101.3 - 2022 DCOF (dynamic coefficient of friction). Therefore, the topcoat system is NSF61 certified, aliphatic, and / or has high abrasion resistance.

[0103] NSF / ANSI 61 focuses on evaluating contaminants or impurities generated by products in contact with drinking water. Unusual or unexpected impurities usually depend on the manufacturing method and the quality of raw materials. This standard provides basic criteria for promoting hygiene and protecting public health.

[0104] Ultraviolet color stability simulates environmental conditions of sunlight exposure, heat, and humidity to compare the tolerance of paints, plastics, or fabrics to these conditions. Quantifiable results are recorded through changes in gloss and / or color readings.

[0105] NFSI B101.3 - 2022 DCOF measures the ratio of the force required to keep a surface already in motion sliding on another surface to the weight of the object. Unless otherwise specified for the project, a DCOF of.42 or greater is required to be measured on a wet surface.

[0106] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit can be combined with any upper limit to recite ranges not explicitly recited, and similarly, ranges from any lower limit can be combined with any other lower limit to recite ranges not explicitly recited, and similarly, ranges from any upper limit can be combined with any other upper limit to recite ranges not explicitly recited. In addition, even if not explicitly recited, each point or individual value between the endpoints of a range is included within the range. Thus, each point or individual value can serve as its own lower or upper limit and be combined with any other point or individual value or any other lower or upper limit to recite ranges not explicitly recited.

[0107] All numerical values in the detailed description herein are modified with the indicia of "about" and account for experimental errors and variations expected by a person of ordinary skill in the art.

[0108] All documents described herein are incorporated herein by reference, including any priority documents and / or test procedures, provided they are not inconsistent with this document. From the foregoing general description and the detailed description, it is clear that while the form of the present disclosure has been shown and described, various modifications can be made without departing from the spirit and scope of the present disclosure. Accordingly, the present disclosure is not intended to be limited thereby. Similarly, under U.S. law, the term "comprising" is considered synonymous with the term "including." Similarly, whenever a composition, element, or group of elements is introduced by the transitional phrase "comprising," it should be understood that we also contemplate the same composition or group of elements described with the transitional phrases "consisting essentially of," "consisting of," "selected from the group consisting of," or "is" at the beginning, and vice versa.

[0109] Although the present disclosure has been described with respect to multiple embodiments and examples, those skilled in the art will recognize, after benefiting from the present disclosure, that other embodiments can be designed that do not depart from the scope and spirit of the present disclosure.

Claims

1. A coated substrate, comprising: a substrate; a first elastomeric coating disposed on the substrate, the first elastomeric coating comprising a first elastomer selected from the group consisting of: polyureas, polyurethanes, polyurea - polyurethane copolymers, and combinations thereof; and a second elastomeric coating disposed on the first elastomeric coating, the second elastomeric coating being substantially sulfur - free and comprising a second elastomer selected from the group consisting of: polyureas, polyurethanes, polyurea - polyurethane copolymers, and combinations thereof, wherein the first elastomer is the same as or different from the second elastomer, and at least one of the first elastomer or the second elastomer is a polyurea - polyurethane copolymer.

2. The coated substrate according to claim 1, further comprising a plurality of abrasives disposed between a first surface of the first elastomeric coating and a first surface of the second elastomeric coating, wherein the second elastomeric coating has a plurality of protrusions at a second surface of the second elastomeric coating opposite the first surface of the second elastomeric coating.

3. The coated substrate according to claim 1, wherein the thickness of the first elastomeric coating is from about 20 mils to about 100 mils.

4. The coated substrate according to claim 3, wherein the thickness of the second elastomeric coating is from about 15 mils to about 40 mils.

5. The coated substrate according to claim 1, wherein the total thickness of the first elastomeric coating and the second elastomeric coating is from about 40 mils to about 200 mils.

6. The coated substrate according to claim 1, wherein the substrate comprises a geotextile sheet containing woven or non - woven fabric.

7. The coated substrate according to claim 1, wherein the substrate comprises a foam having a density of from about 1 lb / ft 3 to about 3 lb / ft 3 3.

8. The coated substrate according to claim 2, wherein the abrasives of the plurality of abrasives are selected from the group consisting of: sand, cinder, alumina, rubber granules, ceramic beads, glass beads, and combinations thereof.

9. The coated substrate according to claim 8, wherein the abrasives of the plurality of abrasives are substantially spherical and have an average particle size of from about 0.5 mm to about 1.5 mm.

10. The coated substrate according to claim 8, wherein the first surface of the first elastomeric coating has a percentage covered by the plurality of abrasives of from about 0.1 oz / ft 2 to about 1 oz / ft 2 .

11. The coated substrate according to claim 1, wherein the second elastomer is a polyurea - polyurethane copolymer.

12. The coated substrate according to claim 11, wherein the second elastomer has: a hardness (Shore D) of from about 55 D to about 65 D as measured according to ASTM D - 2240, a tear strength of from about 400 PLI to about 800 PLI as measured according to ASTM D - 624, a tensile strength of from about 2000 PSI to about 4000 PSI as measured according to ASTM D - 412, and an elongation at break of from about 500% to about 750% as measured according to ASTM D - 412.

13. The coated substrate according to claim 1, wherein each of the first elastomer and the second elastomer is a polyurea - polyurethane copolymer.

14. A water body, comprising: a liquid storage area; and the coated substrate according to claim 1, disposed on the liquid storage area.

15. A method, comprising: Construct a barrier around a site including a leveled foundation pad; and Cover the foundation pad with the coated substrate according to claim 1.

16. A method of manufacturing a coated substrate, the method comprising: Applying a first liquid elastomer to a substrate at a first fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit to form a first elastomer coating; and Applying a second liquid elastomer to the first elastomer coating at a second fluid temperature of about 100 degrees Fahrenheit to about 200 degrees Fahrenheit during a time period of about 5 seconds to about 5 minutes after forming the first elastomer coating to form a second elastomer coating disposed on the first elastomer coating, the second elastomer coating being substantially sulfur-free, wherein the second fluid temperature is the same as or different from the first fluid temperature.

17. The method according to claim 16, wherein the first elastomer coating comprises a first elastomer and the second elastomer coating comprises a second elastomer the same as or different from the first elastomer, wherein each of the first elastomer and the second elastomer is independently selected from the group consisting of: polyureas, polyurethanes, polyurea-polyurethane copolymers, and combinations thereof.

18. The method according to claim 17, wherein the time is about 5 seconds to about 30 seconds.

19. The method according to claim 17, wherein the time is about 30 seconds to about 2 minutes.

20. The method according to claim 17, further comprising applying a plurality of abrasives to the first elastomer coating during the setting time of the first elastomer coating.

21. The method according to claim 20, wherein the second elastomer is a polyurea-polyurethane copolymer.

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