Anti-corrosion, wear-resistant and anti-skid deck coating system and preparation method thereof

Abstract

The invention discloses an anti-corrosion, wear-resistant and anti-skid deck coating system and a preparation method thereof. The coating system is composed of a bi-component epoxy zinc-rich primer and a bi-component polyurethane elastomer finish. The double-component epoxy zinc-rich primer is formed by mixing a component A1 and a component B1 according to a mass ratio; the component A1 comprises epoxy resin, extender pigment, zinc powder and a diluent; the component B1 comprises an amine prepolymer and a diluent; the two-component polyurethane elastomer finish paint is formed by mixing a component A2 and a component B2 according to a mass ratio; the component A2 comprises a polyurethane elastomer, a pigment filler, an auxiliary agent and a diluent; and the component B2 is an isocyanate curing agent. The coating system disclosed by the invention has excellent corrosion resistance, wear resistance and skid resistance in a dry state, a wet state and an oil state, has very good pulverization resistance and cracking resistance under marine climate exposure, and has very long service life compared with common epoxy and polyurethane coating systems in the market.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of coatings, and particularly relates to a kind of anticorrosive wear-resistant antiskid deck coating system and its preparation method. BACKGROUND

[0002] With the increasingly mature development and utilization of marine resources in China, marine engineering equipment such as ships and offshore platforms are increasingly applied, and the demand for antiskid coating for deck surface is increasing. Since the deck part is prone to water collection and condensation, and the open deck part directly contacts with the atmosphere, is eroded by wind and rain, is exposed to sunlight, and is subjected to the action of sea water dry-wet alternation, etc., the deck coating is required to have excellent corrosion resistance, water resistance, weather resistance and adhesion. In addition, due to personnel activities and mechanical operations, the deck is often subjected to stepping friction and rolling wear, and is easily contaminated by various oily, acidic and alkaline media, and needs to be frequently scrubbed, etc., so the deck coating is required to have good antiskid property, wear resistance, oil resistance and acid and alkali resistance, and also needs to be resistant to scrubbing. The deck antiskid coating mainly increases the friction to improve the antiskid property of the surface, effectively reducing the sliding property of personnel, vehicles and other objects such as aircraft. The hardness and friction coefficient of the traditional deck antiskid coating can meet the requirements in the early stage of use, but as the time of exposure to harsh marine environment continues to increase, the antiskid and wear resistance of the coating decreases sharply, and the maintenance and replacement work of the coating in the later stage is complicated and complex, with high maintenance cost.

[0003] A kind of ship deck surface antiskid wear-resistant coating and its preparation method are disclosed in Chinese patent with application number CN201711295544.5 and publication date 2020-01-03, which uses epoxy resin as the main component, combined with graphene, carbon fiber powder, paeonol, dibutyl phthalate, silicon dioxide, titanium dioxide, silicon carbide and polyamide, and forms a ship deck surface antiskid wear-resistant coating after uniform ball milling and stirring and rolling. The epoxy resin used in this patent is used as the base material of the deck coating, but the epoxy resin itself cannot provide sufficient antiskid property and wear resistance; and the weather resistance of the epoxy resin is poor, and long-term exposure to marine atmospheric environment can cause problems such as powdering and failure; and the added graphene filler is easy to agglomerate due to van der Waals force, and is difficult to uniformly disperse in the coating matrix, in addition, the interface bonding mechanism of graphene and resin has not been completely analyzed, and coating failure may occur after long-term use.

[0004] Chinese patent application number CN202011334616.4, published on 2021-11-16, discloses an anti-slip and wear-resistant polyurethane deck paint and its preparation method. It uses a composite resin matrix of hydroxyl acrylic resin and polyester polyol or polyether polyol, along with modified silica, alumina, or silicon carbide inorganic particles as anti-slip and wear-resistant fillers. An interpenetrating network is formed through cross-linking with an isocyanate curing agent, improving compatibility and wear resistance. The coating is suitable for large-area application via spraying. However, this coating system is relatively simple, and its resistance to salt spray, salt water, alkali, and sodium dodecylbenzene sulfonate is short-lived. Furthermore, its corrosion resistance under marine exposure is not described. Summary of the Invention

[0005] This invention is proposed to solve the problems existing in the prior art, and its purpose is to provide an anti-corrosion, wear-resistant and anti-slip deck coating system and its preparation method.

[0006] This invention is achieved through the following technical solution:

[0007] A corrosion-resistant, wear-resistant, and anti-slip deck coating system, wherein the coating system consists of a two-component epoxy zinc-rich primer and a two-component polyurethane elastomer topcoat; the dry film thickness ratio of the two-component epoxy zinc-rich primer and the two-component polyurethane elastomer topcoat is 1:(4-6).

[0008] The two-component epoxy zinc-rich primer is made by mixing component A1 and component B1 in a mass ratio of (7-8):1. Before application, component A1 and component B1 are mixed evenly.

[0009] The components included in component A1 and the mass percentage of each component are as follows:

[0010]

[0011] The epoxy resin in component A1 is composed of a medium molecular weight bisphenol A type epoxy resin and a multifunctional epoxy resin, with a mass ratio of (6-8):1. The medium molecular weight bisphenol A type epoxy resin is a commercially available bisphenol A epoxy resin with a molecular weight of 700-2000. The multifunctional epoxy resin is a multifunctional epoxy resin containing at least three epoxy groups in its molecule, such as TGPAP triglycidyl-p-aminophenol, which is formed by the condensation of commercially available polyamines and epichlorohydrin.

[0012] The extender pigment in component Al is any one or more of talc, organobentonite, mica powder, or precipitated barium sulfate.

[0013] The zinc powder in component Al is 1000-mesh spherical zinc powder.

[0014] The components included in component B1 and the mass percentage of each component are as follows:

[0015] amine prepolymers 20%–25%;

[0016] Diluent balance.

[0017] The amine prepolymer in component B1 is prepared by reacting epoxy resin with an epoxy equivalent of 450 g / eq to 500 g / eq and an amine under the action of an accelerator; the amine is triethylenetetramine and / or diethylenetriamine; the mass ratio of epoxy resin to amine is 1:(2 to 2.5); the accelerator is a tertiary amine, and the mass ratio of epoxy resin to accelerator is (3 to 4):1.

[0018] The two-component polyurethane elastomer topcoat is made by mixing component A2 and component B2 in a mass ratio of (5-6.5):1. Before application, component A2 and component B2 should be mixed evenly.

[0019] The components included in component A2 and the mass percentage of each component are as follows:

[0020]

[0021] The polyurethane elastomer in component A2 is composed of hydroxyl acrylic resin and saturated polyester resin, with a mass ratio of hydroxyl acrylic resin to saturated polyester resin of (4-5):1.

[0022] The hydroxyl acrylic resin has excellent weather resistance and drying properties, with a solid content of 60% to 70%, a hydroxyl content (solid resin, OH%) of 2.0% to 3.0%, a viscosity of 3400 mPa.s to 6500 mPa.s at 25°C, and an acid value of 6 mg KOH / g to 15 mg KOH / g.

[0023] The saturated polyester resin has wear resistance and excellent elasticity, good compatibility with acrylic resin, a solid content of 75% to 80%, a viscosity of 2000 mPa.s to 4000 mPa.s at 25°C, a hydroxyl content (solid resin, OH%) of 3.5% to 4.5%, and an acid value of less than 10 mg KOH / g.

[0024] The pigments and fillers in component A2 are any one or more of sericite, barium sulfate, feldspar powder, carbon black, titanium dioxide, lemon yellow, medium chrome yellow, phthalocyanine blue, silicon carbide, alumina, or diamond powder.

[0025] The additives in component A2 are dispersants, leveling agents, defoamers, and thixotropic agents. The dispersant accounts for 20-40% of the mass of pigments and fillers, the leveling agent accounts for 5-8‰ of the total mass of component A2, the defoamer accounts for 3-8‰ of the total mass of component A2, and the thixotropic agent accounts for 2-3% of the mass of pigments and fillers.

[0026] The dispersant is a high molecular weight block copolymer with pigment-loving groups, such as CTR7517 dispersant and BYK23157 from CNOOC Changzhou Environmental Coatings Co., Ltd.

[0027] The leveling agent is a fluorocarbon modified polyacrylate leveling agent, such as AFCONA3777 or AFCONA3700.

[0028] The defoamer is a fluorocarbon-modified organosilicon defoamer, such as AFCONA2040;

[0029] The thixotropic agent is organobentonite.

[0030] The diluent in components A1, A2 and B1 is any one or more of xylene, butanol, butyl acetate, propylene glycol methyl ether acetate or cyclohexanone.

[0031] Component B2 is an isocyanate curing agent; the NCO content of the isocyanate curing agent is 15% to 17%.

[0032] A method for preparing the aforementioned anti-corrosion, wear-resistant, and anti-slip deck coating system includes the following steps:

[0033] (I) Preparation of component A1

[0034] After the epoxy resin of component A1 is evenly dispersed in the diluent, the extender pigment is added and stirred at a speed of 200 rad / min to 300 rad / min for 20 min to 30 min. The mixture is then ground in a grinding device until no obvious particles are visible. 1000 mesh zinc powder is added while stirring, and stirring is continued for more than 1 hour until no obvious particles are visible. The mixture is then filtered through an 80 mesh filter cloth to obtain component A1.

[0035] (II) Preparation of component B1

[0036] After the amine and accelerator are evenly dispersed in the diluent, epoxy resin with an epoxy equivalent of 450 g / eq to 500 g / eq is added. The mixture is stirred at a speed of 200 rad / min to 300 rad / min for 20 min to 30 min, then left to stand for 24 h. The mixture is then filtered through an 80-mesh filter cloth to obtain component B1.

[0037] (III) Preparation of component A2

[0038] After the hydroxyl acrylic resin, saturated polyester resin, dispersant, leveling agent and defoamer are evenly dispersed in the diluent, pigments and fillers are added, and the mixture is stirred at a speed of 200 rad / min to 300 rad / min for 20 min to 30 min. The mixture is then ground in a grinding equipment until there are no obvious particles. After adding the thixotropic agent and stirring evenly, the mixture is filtered and packaged to obtain component A2.

[0039] (IV) Preparation of topcoat and primer

[0040] Before application, mix components A1 and B1 evenly at a mass ratio of (7-8):1 to obtain the epoxy zinc-rich primer of the coating system; mix components A2 and B2 evenly at a mass ratio of (5-6.5):1 to obtain the two-component polyurethane elastomer topcoat of the coating system.

[0041] (V) Construction

[0042] During the construction of the anti-corrosion, wear-resistant, and anti-slip deck coating system, the steel plate surface is first degreased, sandblasted, and dusted to ensure the cleanliness of the substrate surface. Then, a two-component epoxy zinc-rich primer is sprayed, with a dry film thickness of 60μm to 80μm. After drying at room temperature for 24 hours, the first two-component polyurethane elastomer topcoat is sprayed, with a dry film thickness of 180μm to 200μm. After drying at room temperature for 24 hours, the second two-component polyurethane elastomer topcoat is sprayed, with a dry film thickness of 180 to 200μm.

[0043] The beneficial effects of this invention are:

[0044] This invention provides a corrosion-resistant, wear-resistant, and anti-slip deck coating system and its preparation method. Through the matching of the coating system and the synergistic effect of resin and filler, the coating achieves the technical requirements of high wear resistance, high durability, and high friction coefficient, meeting the application needs in the field of marine engineering decks.

[0045] The coating system of this invention has excellent corrosion resistance, wear resistance, and anti-slip properties in dry, wet, and oily conditions. It also has good resistance to chalking and cracking under marine weather conditions and has a much longer service life compared to commonly used epoxy and polyurethane coating systems on the market.

[0046] This invention's coating system uses an epoxy zinc-rich primer and a polyurethane elastomer topcoat in combination. Careful selection of the raw materials and dosages for both the epoxy zinc-rich primer and the polyurethane elastomer topcoat in this high-performance anti-corrosion, wear-resistant, and anti-slip coating system ensures that not only are the individual functions of the epoxy zinc-rich primer and the polyurethane elastomer topcoat fully utilized, but their synergistic effect results in a final coating that combines corrosion resistance with wear resistance and anti-slip properties. The epoxy zinc-rich primer in this invention's coating system uses a combination of medium-molecular-weight epoxy resin and multifunctional epoxy resin to increase crosslinking density, enhance penetration into the substrate, and achieve strong adhesion. Simultaneously, the curing agent is an amine prepolymer, which significantly accelerates the curing speed and shortens the construction period. The polyurethane elastomer topcoat in this invention's coating system, through molecular structure design, increases the number of polar groups on the paint film surface, increasing the van der Waals forces between the paint film and the polar groups on the contact surface, thereby increasing anti-slip properties. Adjusting the ratio of alicyclic and linear isocyanates and the hard segment content balances mechanical strength and flexibility, optimizing the coating's wear resistance. The fire-retardant and wear-resistant filler of the polyurethane elastomer topcoat in the coating system of this invention is designed with composite anti-slip agents to achieve the synergistic effect between different types and particle sizes of anti-slip agents (alumina, silicon carbide, and corundum) on the overall performance of the coating, thereby achieving the technical requirements of high wear resistance and high coefficient of friction of the coating. Detailed Implementation

[0047] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be further described below through specific embodiments.

[0048] Example 1

[0049] A method for preparing an anti-corrosion, wear-resistant, and anti-slip deck coating system includes the following steps:

[0050] (I) Preparation of component A1

[0051] In a mixing container, disperse the epoxy resin evenly in the diluent according to Table 1, add the extender pigment, stir for 30 minutes at a speed of 300 rad / min, and then grind it in a grinding device until there are no obvious particles. Add 1000 mesh zinc powder while stirring, and continue stirring for more than 1 hour until there are no obvious particles. Filter and package to obtain component A1.

[0052] The components included in component A1 and the mass percentage of each component are shown in Table 1:

[0053] Table 1: Formulation of Component A1

[0054]

[0055]

[0056] (II) Preparation of component B1

[0057] In a mixing container, diethylenetriamine and tertiary amine were stirred and dispersed evenly in a diluent according to the formulation of component B1 in Table 2. Then, epoxy resin with an epoxy equivalent of 450 g / eq to 500 g / eq was added. The mixture was stirred at 300 rad / min for 30 min and then left to stand for 24 h. Component B1 was obtained by filtration.

[0058] Table 2: Formulation of Component B1

[0059]

[0060] (III) Preparation of component A2

[0061] In the packaging drum, according to the formulation of component A2 in Table 3, the hydroxyl acrylic resin, saturated polyester resin, leveling agent, dispersant, and defoamer are evenly dispersed in the diluent. Then, pigments and fillers are added, and the mixture is stirred for 20 to 30 minutes at a speed of 200 rad / min to 300 rad / min. The mixture is then ground in a grinding equipment until no obvious particles are visible. After adding the thixotropic agent and stirring evenly, the mixture is filtered and packaged to obtain component A2.

[0062] Table 3: Formulation of Component A2

[0063]

[0064] (IV) Preparation of component B2

[0065] Component B2 is Covestro N-75 curing agent from Germany;

[0066] (V) Preparation of epoxy zinc-rich primer

[0067] Components A1 and B1 are thoroughly mixed at a mass ratio of 7:1 to obtain the epoxy zinc-rich primer of the coating system of the present invention, which is ready for use and has a construction period of 2 hours.

[0068] (VI) Preparation of polyurethane elastomer topcoat

[0069] Mix component A2 and component B2 evenly at a mass ratio of 6:1 to obtain the two-component polyurethane elastomer topcoat of the coating system. Set aside for later use. Application period: 2 hours.

[0070] Performance testing of high-performance anti-corrosion, wear-resistant, and anti-slip deck coating systems:

[0071] 1. Preparation of test samples

[0072] Two sizes of hot-rolled steel plates were provided: one 250mm×150mm×3mm and the other 150mm×75mm×3mm. Both sizes of steel plates underwent degreasing, sandblasting, and dust removal treatment. First, an epoxy zinc-rich primer prepared in Example 5 was applied (dry film thickness 60-70µm). After 24 hours at room temperature, a polyurethane elastomer topcoat prepared in Example 6 was applied (dry film thickness 180-200µm). After another 24 hours at room temperature, the polyurethane elastomer topcoat prepared in Example 6 was applied again (dry film thickness 180-200µm), and then the plates were dried for 14 days and stored for testing.

[0073] 2. Test Results:

[0074] The samples were tested according to relevant standards, and the test results are shown in Table 4.

[0075] Table 4: Performance Test Items and Results of High-Performance Anti-corrosion, Wear-resistant and Anti-skid Deck Coating System

[0076]

[0077]

[0078] As can be seen from the test results in Table 4, the coating system of this invention has significant advantages over the coating of patent application number CN201711295544.5 in terms of corrosion resistance and anti-aging properties under marine climate. Compared with the coating of patent application number CN202011334616.4, in addition to its outstanding performance in corrosion resistance such as media resistance, it also has great advantages in wear resistance and anti-slip properties.

[0079] This invention relates to a high-performance anti-corrosion, wear-resistant, and anti-slip deck coating system. It is easy to prepare and can be applied by spraying, brushing, or roller coating, allowing for flexible construction environments. Moreover, the coating cures quickly at room temperature, producing a dense, glossy, and hard film with strong adhesion. It exhibits excellent marine corrosion resistance and wear-resistant and anti-slip properties, making it an ideal coating for the protective application of deck areas on ships, offshore platforms, and other marine engineering equipment.

[0080] The applicant declares that the above description is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention fall within the protection and disclosure scope of the present invention.

Claims

1. A corrosion-resistant, wear-resistant, and anti-slip deck coating system, characterized in that: The coating system consists of a two-component epoxy zinc-rich primer and a two-component polyurethane elastomer topcoat; the dry film thickness ratio of the two-component epoxy zinc-rich primer and the two-component polyurethane elastomer topcoat is 1:(4-6). The two-component epoxy zinc-rich primer is composed of component A1 and component B1 mixed in a mass ratio of (7-8):1; The components included in component A1 and the mass percentage of each component are as follows: The components included in component B1 and the mass percentage of each component are as follows: amine prepolymers 20%–25%; Diluent balance; The two-component polyurethane elastomer topcoat is composed of component A2 and component B2 mixed in a mass ratio of (5-6.5):1; The components included in component A2 and the mass percentage of each component are as follows: Component B2 is an isocyanate curing agent.

2. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The epoxy resin in component A1 consists of medium molecular weight bisphenol A type epoxy resin and multifunctional epoxy resin.

3. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The extender pigment in component A1 is any one or more of talc, organobentonite, mica powder, or precipitated barium sulfate; the zinc powder in component A1 is 1000-mesh spherical zinc powder.

4. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The amine prepolymer in component B1 is prepared by reacting epoxy resin with an epoxy equivalent of 450 g / eq to 500 g / eq and an amine under the action of an accelerator; the amine is triethylenetetramine and / or diethylenetriamine; the mass ratio of epoxy resin to amine is 1:(2 to 2.5); the accelerator is a tertiary amine, and the mass ratio of epoxy resin to accelerator is (3 to 4):

1.

5. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The polyurethane elastomer in component A2 is composed of hydroxyl acrylic resin and saturated polyester resin.

6. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The pigments and fillers in component A2 are any one or more of sericite, barium sulfate, feldspar powder, carbon black, titanium dioxide, lemon yellow, medium chrome yellow, phthalocyanine blue, silicon carbide, alumina, and diamond powder.

7. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The additives in component A2 are dispersants, leveling agents, defoamers, and thixotropic agents; the dispersant is a high molecular weight block copolymer with pigment-affinity groups; the leveling agent is a fluorocarbon-modified polyacrylate leveling agent; the defoamer is a fluorocarbon-modified organosilicon defoamer; and the thixotropic agent is organobentonite.

8. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The diluent in components A1, A2 and B1 is any one or more of xylene, butanol, butyl acetate, propylene glycol methyl ether acetate or cyclohexanone.

9. The anti-corrosion, wear-resistant, and anti-slip deck coating system according to claim 1, characterized in that: The isocyanate curing agent has an NCO content of 15% to 17%.

10. A method for preparing the anti-corrosion, wear-resistant, and anti-slip deck coating system according to any one of claims 1 to 9, characterized in that: Includes the following steps: (I) Preparation of component A1 After the epoxy resin is evenly dispersed in the diluent, the extender pigment is added, and after stirring, it is ground until there are no obvious particles. Then, zinc powder is added under stirring and stirred until there are no obvious particles. Filter to obtain component A1. (II) Preparation of component B1 After the accelerator is evenly dispersed in the diluent, it is added to the epoxy resin, stirred and left to stand for 24 hours, and then filtered to obtain component B1. (III) Preparation of component A2 After the hydroxyl acrylic resin, saturated polyester resin, dispersant, leveling agent and defoamer are evenly dispersed in the diluent, pigments and fillers are added, stirred and ground until no obvious particles are present; after the thixotropic agent is added and stirred evenly, the mixture is filtered to obtain component A2. (IV) Preparation of primer and topcoat Mixing components A1 and B1 evenly according to the mass ratio yields the epoxy zinc-rich primer of the coating system; mixing components A2 and B2 evenly according to the mass ratio yields the two-component polyurethane elastomer topcoat of the coating system.

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