Styrene-resin-free anticorrosive coating on PS foam surface and preparation method of styrene-resin-free anticorrosive coating

Abstract

The invention discloses a non-styrene resin anti-corrosion coating on a PS foam surface and a preparation method thereof, and belongs to the technical field of new material shipbuilding. The anti-corrosion coating sequentially comprises a bottom coating, a glass fiber cloth reinforcing layer and a surface coating from inside to outside, matrix resin of each layer is styrene-free resin, and the styrene-free resin is vinyl ester resin, epoxy resin or modified acrylic resin. The preparation method comprises the steps of PS foam surface pretreatment, styrene-free resin preparation, priming coat coating, glass fiber cloth laying, infiltrating and pasting, finish coat coating and curing treatment. The styrene-free resin is adopted as a coating material, the problem that styrene monomers in traditional polyester resin corrode PS foam is solved, the coating is endowed with high mechanical strength through glass fiber cloth reinforcement, and the coating is simple in process, low in cost and suitable for the fields of shipbuilding, building heat preservation and the like.

Description

Technical Field

[0001] This invention relates to the field of building facility management technology, and more particularly to a styrene-free resin anti-corrosion coating for PS foam surface and its preparation method. Background Technology

[0002] PS foam is a foamed material based on polystyrene. It boasts advantages such as low density, light weight, low cost, good thermal insulation, and easy processing and molding, making it widely used in shipbuilding, building insulation, packaging and transportation, and floating body manufacturing. In practical applications, to improve the surface strength, abrasion resistance, and weather resistance of PS foam, it is usually necessary to coat its surface with resin and then lay fiberglass cloth to form a composite structural layer. Traditional processes often use unsaturated polyester resin as the coating material, with styrene monomer as the reactive diluent and crosslinking agent. The styrene content is typically between 30% and 40%.

[0003] Because the matrix material of PS foam is polystyrene, whose molecular structure is similar to that of styrene monomers, according to the principle of "like dissolves like," the styrene monomers in unsaturated polyester resin will have a strong corrosive effect on PS foam, causing the foam surface to collapse, deform, or even completely dissolve, preventing the coating from forming properly and seriously affecting product quality and performance. Current solutions mainly include pre-coating the PS foam surface with an isolation layer or using resins with low styrene content. However, the isolation layer process increases production steps and costs, and even low-styrene resins cannot completely prevent corrosion. Therefore, developing a resin coating system that can be directly applied to the PS foam surface without causing corrosion has significant practical value. Summary of the Invention

[0004] The purpose of this invention is to provide a method for preparing a styrene-free resin anti-corrosion coating on the surface of PS foam, so as to solve the problems existing in the prior art.

[0005] This invention provides a styrene-free resin anti-corrosion coating for PS foam surface. The anti-corrosion coating includes, from the inside out, a base coating, a fiberglass cloth reinforcement layer, and a top coating. The base resins of the base coating, the fiberglass cloth reinforcement layer, and the top coating are all styrene-free resins. The styrene-free resin is a vinyl ester resin, an epoxy resin, or a modified acrylic resin. The fiberglass cloth reinforcement layer is formed by impregnating fiberglass cloth with styrene-free resin.

[0006] The above technical solution employs a three-layer composite structure consisting of a base coating, a fiberglass reinforcement layer, and a top coating, arranged sequentially from the inside out. Each layer uses vinyl ester resin, epoxy resin, or modified acrylic resin that is styrene-free. Because the styrene-free resin does not contain styrene monomers in its molecular structure, there is no issue of similarity-to-miscibility with the PS foam substrate. Therefore, it will not cause corrosion to the PS foam during the coating process, fundamentally solving the technical problem of traditional polyester resin corroding PS foam. Simultaneously, after the fiberglass reinforcement layer is fully impregnated with the styrene-free resin, it forms an integrated composite structure with the base coating and top coating, significantly improving the mechanical strength and flexural strength of the coating. This creates a protective layer on the PS foam surface with both corrosion resistance and structural strength, expanding the application range of PS foam in shipbuilding and construction.

[0007] A method for preparing a styrene-free resin anti-corrosion coating on the surface of PS foam includes the following steps: S1. PS foam surface pretreatment: Clean the PS foam surface to remove dust, oil and impurities. Wipe the surface with anhydrous ethanol and let it dry before use. S2. Preparation of styrene-free resin: Mix the styrene-free resin main agent with the curing agent, stir evenly, and let stand to defoam; S3. Primer coating: The prepared styrene-free resin is evenly coated onto the surface of PS foam to form a primer coating. S4. Fiberglass cloth laying: With the base coating surface wet, lay the fiberglass cloth flat on the coating surface; S5. Impregnation and paste preparation: Coat the surface of the fiberglass cloth with styrene-free resin, allowing the resin to fully impregnate the fiberglass cloth and eliminate air bubbles; S6. Topcoat coating: After the impregnation layer has initially cured, apply styrene-free resin as a topcoat to the surface of the fiberglass cloth. S7. Curing treatment: Place the coated PS foam in a room temperature environment for curing.

[0008] Further, in step S2, the mass ratio of the styrene-free resin main agent to the curing agent is 100:1 to 100:3; when the styrene-free resin main agent is vinyl ester resin, the curing agent is methyl ethyl ketone peroxide or benzoyl peroxide; when the styrene-free resin main agent is epoxy resin, the curing agent is a modified fatty amine curing agent; when the styrene-free resin main agent is modified acrylic resin, the curing agent is an isocyanate curing agent.

[0009] Furthermore, in step S2, when the styrene-free resin main agent is vinyl ester resin, an accelerator is also added. The amount of accelerator added is 0.5% to 2% of the mass of the resin main agent, and the accelerator is a cobalt naphthenate solution; the standing defoaming time is 5 to 10 minutes.

[0010] Further, in step S3, the amount of the base coating is 150 to 250 grams per square meter, and the coating thickness is 0.2 to 0.4 millimeters; in step S5, the amount of the impregnation resin is 200 to 350 grams per square meter; in step S6, the amount of the topcoat is 100 to 200 grams per square meter, and the coating thickness is 0.15 to 0.3 millimeters.

[0011] Furthermore, in step S4, the fiberglass cloth is alkali-free fiberglass cloth with a surface density of 200 to 450 grams per square meter; the overlap width of adjacent fiberglass cloths is 20 to 30 millimeters.

[0012] Furthermore, in step S7, the curing temperature is 20 to 30 degrees Celsius, the curing time is 12 to 24 hours, and the relative humidity of the curing environment is controlled below 70%.

[0013] Furthermore, the glass fiber cloth laying and impregnation paste-making operations are repeated once or multiple times between steps S4 and S6 to form a multi-layer glass fiber cloth reinforced composite structure.

[0014] The beneficial effects of this invention are: 1. This invention uses styrene-free resin as the coating matrix material. The molecular structure of styrene-free resin does not contain styrene monomers, so it will not cause corrosion to the PS foam substrate during the coating process. This effectively solves the problem of corrosion of PS foam by traditional unsaturated polyester resin. The coating and the substrate can form a good bonding interface with an adhesion level of 0 to 1.

[0015] 2. This invention forms a reinforcing layer by pasting glass fiber cloth into a styrene-free resin coating. The glass fiber cloth and the resin matrix form a composite structure, which significantly improves the mechanical strength of the coating. The flexural strength of a single-layer glass fiber cloth reinforced coating can reach 78.4 to 92.3 MPa, and the flexural strength of a double-layer reinforced structure can reach 118.5 MPa, thus providing a high-strength protective layer for the surface of low-density PS foam.

[0016] 3. The preparation method of the present invention is simple and does not require pre-coating an isolation layer on the surface of PS foam, which reduces production steps and lowers production costs; the curing process is carried out at room temperature, without the need for heating equipment, resulting in low energy consumption; the prepared anti-corrosion coating has good solvent resistance and can effectively block organic solvents from penetrating into the PS foam substrate, thus extending the service life of PS foam products. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for this invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the coating structure of the present invention; Figure 2 This is a flowchart of the preparation method of the present invention. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should also be noted that, to make the embodiments more comprehensive, the following embodiments are the best and preferred embodiments, and those skilled in the art can use other alternative methods to implement some well-known technologies; moreover, the accompanying drawings are only for more specific description of the embodiments and are not intended to specifically limit the present invention.

[0020] It should be noted that the use of terms such as "an embodiment," "an embodiment," "an exemplary embodiment," and "some embodiments" in the specification indicates that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments (whether explicitly described or not) should be within the knowledge of those skilled in the art.

[0021] Generally, terms can be understood at least partly from their use in context. For example, depending at least partly on the context, the term "one or more" as used herein can be used to describe any feature, structure, or characteristic in a singular sense, or a combination of features, structures, or characteristics in a plural sense. Additionally, the term "based on" can be understood not necessarily to convey an exclusive set of factors, but rather, alternatively, depending at least partly on the context, to allow for the presence of other factors that are not necessarily explicitly described.

[0022] See Figures 1 to 2 As shown This invention provides a method for preparing a styrene-free resin anti-corrosion coating on the surface of PS foam. The method involves coating the PS foam surface with a styrene-free resin and then attaching a glass fiber cloth 2 to form a composite coating with anti-corrosion properties and structural strength. The styrene-free resin refers to a resin whose molecular structure does not contain styrene monomers, specifically including vinyl ester resin, epoxy resin, or modified acrylic resin.

[0023] The method for preparing the styrene-free resin anti-corrosion coating includes the following steps: S1. PS Foam Surface Pretreatment: Clean the PS foam surface to remove dust, oil, and impurities. Wipe the surface with anhydrous ethanol and allow it to dry completely before use. The cleaned PS foam surface should be kept dry and clean, with a moisture content controlled below 0.5%.

[0024] S2. Preparation of styrene-free resin: Mix the styrene-free resin main agent and curing agent at a mass ratio of 100:1 to 100:3, stir evenly, and let stand for 5 to 10 minutes to defoam. The curing agent is methyl ethyl ketone peroxide or benzoyl peroxide. An accelerator may be added as needed during the preparation process. The amount of accelerator added is 0.5% to 2% of the mass of the resin main agent, and the accelerator is a cobalt naphthenate solution.

[0025] S3. Applying the first base coat: Using a brush or roller, evenly apply the prepared styrene-free resin to the surface of the PS foam to form the first base coat 1. The application amount of the base coat 1 should be controlled at 150 to 250 grams per square meter, and the coating thickness should be 0.2 to 0.4 millimeters. During application, maintain uniform pressure to avoid missed areas or accumulation.

[0026] S4. Laying of Fiberglass Cloth 2: With the base coating 1 surface moist, lay the pre-cut fiberglass cloth 2 flat on the coating surface. The areal density of the fiberglass cloth 2 is 200 to 450 grams per square meter. The fiberglass cloth 2 should be laid flat to avoid wrinkles, bubbles, or uneven overlap. The overlap width of adjacent fiberglass cloths 2 should be controlled between 20 and 30 millimeters.

[0027] S5. Impregnation and Paste Application: Apply styrene-free resin again to the surface of the fiberglass cloth 2 using a brush or roller, ensuring the resin fully impregnates the fiberglass cloth 2 and eliminating air bubbles between the fiberglass cloth and the resin layer. The amount of resin applied for impregnation is 200 to 350 grams per square meter. During operation, roll from the center outwards to ensure the fiberglass cloth 2 is completely impregnated and tightly bonded to the base coating 1.

[0028] S6. Topcoat 3 Application: After the impregnation layer has initially cured, apply a second layer of styrene-free resin as topcoat 3 to the surface of the fiberglass cloth 2. The amount of topcoat 3 applied is 100 to 200 grams per square meter, and the thickness is 0.15 to 0.3 millimeters. Topcoat 3 should be uniform and smooth, forming a smooth surface.

[0029] S7. Curing Treatment: Place the coated PS foam in a room temperature environment for curing. The curing temperature is 20 to 30 degrees Celsius, and the curing time is 12 to 24 hours. During the curing process, maintain good ventilation and keep the relative humidity below 70%. After curing, the coating surface should be non-sticky and have a Shore hardness of D40 or higher.

[0030] Depending on the specific application requirements, the fiberglass cloth 2 laying and impregnation processes can be repeated between steps S4 and S6 to form a multi-layer composite structure, thereby improving the structural strength and protective performance of the coating. Each additional layer of fiberglass cloth 2 can increase the flexural strength of the coating by 15% to 25%.

[0031] Example 1 This embodiment provides a method for preparing an anti-corrosion coating on the surface of PS foam using vinyl ester resin. The specific steps are as follows: Select PS foam boards with a density of 20 kg / m³ and dimensions of 500 mm × 500 mm × 50 mm. Clean the foam surface with anhydrous ethanol and dry it at 25 degrees Celsius for 30 minutes.

[0032] Bisphenol A epoxy vinyl ester resin was selected as the styrene-free resin base, with a viscosity of 350 to 450 mPa·s. 100 parts by weight of vinyl ester resin were mixed with 1.5 parts by weight of methyl ethyl ketone peroxide curing agent, and 1 part by weight of cobalt naphthenate accelerator was added simultaneously. The mixture was stirred for 5 minutes until homogeneous, and then allowed to stand for 8 minutes to defoam.

[0033] The prepared resin is evenly coated onto the PS foam surface using a wool roller, with a base coat amount of 180 grams per square meter. While the base coat is still wet, an alkali-free fiberglass cloth 2 with a surface density of 300 grams per square meter is laid down. A rigid rubber roller is used to roll the cloth from the center outwards to remove air bubbles and ensure the resin fully impregnates the fiber cloth. The resin coating amount for the impregnation layer is 280 grams per square meter.

[0034] After the impregnation layer is touch-dry, apply the topcoat resin 3 at a rate of 150 grams per square meter. Place the coated sample in an environment of 25 degrees Celsius and 60% relative humidity for 18 hours to cure, resulting in a styrene-free resin anti-corrosion coating on the PS foam surface.

[0035] Example 2 This embodiment provides a method for preparing an anti-corrosion coating on the surface of PS foam using epoxy resin. The specific steps are as follows: Select PS foam boards with a density of 25 kg / m³ and dimensions of 500 mm × 500 mm × 50 mm. Clean the foam surface with anhydrous ethanol and dry it at 28 degrees Celsius for 25 minutes.

[0036] Bisphenol A type epoxy resin E-51 was selected as the styrene-free resin main agent, with an epoxy equivalent of 185 to 195 g / mL. 100 parts by weight of epoxy resin were mixed with 25 parts by weight of modified fatty amine curing agent, stirred for 8 minutes until homogeneous, and allowed to stand for 10 minutes to defoam.

[0037] Using a boar bristle brush, evenly apply the prepared resin to the PS foam surface, with a base coat application rate of 200 grams per square meter. While the base coat is still wet, lay down an alkali-free fiberglass cloth 2 with a surface density of 200 grams per square meter. Use an aluminum defoaming roller to roll from the center outwards to remove air bubbles and ensure the resin fully impregnates the fiber cloth. The resin application rate for the impregnation layer is 250 grams per square meter.

[0038] After the impregnation layer is touch-dry, apply the topcoat resin 3 at a rate of 120 grams per square meter. Place the coated sample in an environment of 28 degrees Celsius and 55% relative humidity for 24 hours to cure, resulting in a styrene-free resin anti-corrosion coating on the PS foam surface.

[0039] Example 3 This embodiment provides a method for preparing an anti-corrosion coating on the surface of PS foam using modified acrylic resin. The specific steps are as follows: PS foam boards with a density of 18 kg / m³ and dimensions of 500 mm × 500 mm × 50 mm were selected. The foam surface was cleaned with anhydrous ethanol and dried at 22 degrees Celsius for 35 minutes.

[0040] Waterborne hydroxyl acrylic resin was selected as the main agent of the styrene-free resin, with a solid content of 45% to 50% and a hydroxyl content of 3% to 4%. 100 parts by weight of acrylic resin were mixed with 8 parts by weight of isocyanate curing agent, stirred for 6 minutes until uniform, and allowed to stand for 5 minutes to defoam.

[0041] The prepared resin is evenly coated onto the PS foam surface using a wool roller, with a base coat amount of 220 grams per square meter. While the base coat is still wet, an alkali-free fiberglass cloth 2 with a surface density of 450 grams per square meter is laid down. A rigid rubber roller is used to roll the cloth from the center outwards, removing air bubbles and ensuring the resin fully impregnates the fiber cloth. The resin coating amount for the impregnation layer is 320 grams per square meter.

[0042] After the impregnation layer is touch-dry, apply the topcoat resin 3 at a rate of 180 grams per square meter. Place the coated sample in an environment of 22 degrees Celsius and 65% relative humidity for 20 hours to cure, resulting in a styrene-free resin anti-corrosion coating on the PS foam surface.

[0043] Example 4 This embodiment provides a method for preparing an anti-corrosion coating on the surface of PS foam reinforced with double-layer glass fiber cloth 2. The specific steps are as follows: PS foam boards with a density of 22 kg / m³ and dimensions of 500 mm × 500 mm × 50 mm were selected. The foam surface was cleaned with anhydrous ethanol and dried at 25 degrees Celsius for 30 minutes.

[0044] Phenolic epoxy vinyl ester resin was selected as the styrene-free resin base, with a viscosity of 400 to 500 mPa·s. 100 parts by weight of vinyl ester resin were mixed with 2 parts by weight of methyl ethyl ketone peroxide curing agent, and 1.2 parts by weight of cobalt naphthenate accelerator were added simultaneously. The mixture was stirred for 6 minutes until homogeneous, and then allowed to stand for 8 minutes to defoam.

[0045] The prepared resin is evenly coated onto the PS foam surface using a wool roller, with a base coat amount of 200 grams per square meter. While the base coat is wet, a first layer of alkali-free fiberglass cloth 2 with a density of 200 grams per square meter is laid and impregnated using a rigid rubber roller, with a resin coating amount of 230 grams per square meter.

[0046] After the first layer of fiberglass cloth 2 is impregnated, a second layer of alkali-free fiberglass cloth 2 with a density of 300 g / m² is laid and impregnated by roller pressing. The resin coating amount for the impregnated layer is 300 g / m². After the impregnated layer is touch-dry, a topcoat resin 3 is applied with a coating amount of 160 g / m². The coated sample is then cured for 22 hours at 25°C and 58% relative humidity to obtain a styrene-free resin anti-corrosion coating on the surface of PS foam reinforced with double-layer fiberglass cloth 2.

[0047] Comparative Example 1 This comparative example uses traditional unsaturated polyester resin to prepare PS foam surface coating 3. The specific steps are as follows: Select PS foam boards with a density of 20 kg / m³ and dimensions of 500 mm × 500 mm × 50 mm. Clean the foam surface with anhydrous ethanol and dry it at 25 degrees Celsius for 30 minutes.

[0048] Phthalic unsaturated polyester resin was selected as the coating material. This resin contains styrene monomer as a crosslinking agent, and the styrene content is 35% to 40%. 100 parts by weight of the unsaturated polyester resin were mixed with 1.5 parts by weight of methyl ethyl ketone peroxide curing agent, and 1 part by weight of cobalt naphthenate accelerator was added simultaneously. The mixture was stirred for 5 minutes until homogeneous.

[0049] The prepared resin was applied to the PS foam surface using a wool roller. During the application process, obvious corrosion immediately appeared on the PS foam surface. The styrene monomer in the resin had a strong corrosive effect on the PS foam, causing the foam surface to collapse and deform, and the coating could not form properly. The fiberglass cloth 2 was then laid, but due to the severe corrosion of the foam substrate, it could not be laid flat, and large areas of the coating separated from the substrate.

[0050] Comparative Example 2 This comparative example uses styrene-free resin but without glass fiber cloth 2 reinforcement. The specific steps are as follows: Select PS foam boards with a density of 20 kg / m³ and dimensions of 500 mm × 500 mm × 50 mm. Clean the foam surface with anhydrous ethanol and dry it at 25 degrees Celsius for 30 minutes.

[0051] Bisphenol A epoxy vinyl ester resin was selected as the coating material. 100 parts by weight of vinyl ester resin were mixed with 1.5 parts by weight of methyl ethyl ketone peroxide curing agent, and 1 part by weight of cobalt naphthenate accelerator was added simultaneously. The mixture was stirred for 5 minutes until homogeneous, and then allowed to stand for 8 minutes to defoam.

[0052] The prepared resin was evenly coated onto the PS foam surface using a wool roller, with two coats applied, for a total coating weight of 400 grams per square meter. The coated sample was then cured for 18 hours at 25 degrees Celsius and 60% relative humidity. The cured coating surface was smooth and bonded well to the PS foam substrate, but the overall strength of the coating was low, lacking the reinforcing effect of the fiberglass cloth.

[0053] Comparative Example 3 In this comparative example, a PS foam surface coating 3 was prepared using isophthalic unsaturated polyester resin. The specific steps are as follows: Select PS foam boards with a density of 20 kg / m³ and dimensions of 500 mm × 500 mm × 50 mm. Clean the foam surface with anhydrous ethanol and dry it at 25 degrees Celsius for 30 minutes.

[0054] An isophthalic unsaturated polyester resin was selected as the coating material. This resin contains styrene monomer as a crosslinking agent, and the styrene content is 30% to 35%. 100 parts by weight of the unsaturated polyester resin were mixed with 1.5 parts by weight of methyl ethyl ketone peroxide curing agent, and 1 part by weight of cobalt naphthenate accelerator was added simultaneously. The mixture was stirred for 5 minutes until homogeneous.

[0055] The prepared resin was applied to the surface of PS foam using a wool roller. During the application process, the PS foam surface showed signs of erosion. Although the degree of erosion was slightly less than that of the phthalic resin in Comparative Example 1, the foam surface still showed obvious depressions and deformations, and the coating thickness was uneven, making it impossible to proceed with the subsequent fiberglass cloth 2 laying operation.

[0056] Performance testing Performance tests were conducted on the samples prepared in Examples 1 to 4 and Comparative Examples 1 to 3. The tests included: observation of PS foam corrosion, coating-substrate adhesion testing, coating flexural strength testing, coating surface hardness testing, and solvent resistance testing. The test methods and results are as follows: PS foam corrosion status: Visually observe the corrosion status of the PS foam substrate during and after coating, and record whether there is dissolution, collapse or deformation on the foam surface.

[0057] Adhesion test: The cross-cut adhesion test is conducted according to GB / T9286-2021 standard. A grid with a spacing of 2 mm is drawn on the coating surface using a cross-cutting tool. After applying and removing the grid with tape, the degree of coating peeling is observed, and the adhesion level is evaluated. Level 0 is the best, and level 5 is the worst.

[0058] Bending strength test: Three-point bending test was performed according to GB / T9341-2008 standard. The specimen size was 80 mm × 10 mm × 4 mm, the span of the support point was 64 mm, the loading speed was 2 mm per minute, and the maximum bending stress at the time of specimen fracture was recorded.

[0059] Surface hardness test: The Shore D hardness of the coating surface was measured using a Shore hardness tester. Five points were tested for each sample, and the average value was taken.

[0060] Solvent resistance test: The sample was immersed in acetone solvent for 24 hours, and the changes in the appearance of the coating and the corrosion of the PS foam substrate were observed.

[0061] Table 1. Performance test results for each embodiment and comparative example.

[0062] Table 2 Performance test results for Comparative Example 3

[0063] Results Analysis As can be seen from the test results in Tables 1 and 2, the anti-corrosion coatings on the PS foam surface prepared with styrene-free resin in Examples 1 to 4 all exhibit excellent performance. During the coating process, the styrene-free resin does not corrode the PS foam substrate, and a good bonding interface can be formed between the coating and the substrate.

[0064] Example 1 uses vinyl ester resin, achieving an adhesion grade of 0, a flexural strength of 85.6 MPa, and a surface hardness of Shore D52, demonstrating excellent overall performance. Example 2 uses epoxy resin; due to the high crosslinking density after curing, its flexural strength reaches 92.3 MPa, and its surface hardness reaches Shore D58, showing the best performance among all examples. Example 3 uses modified acrylic resin; although its flexural strength and surface hardness are slightly lower than those of Examples 1 and 2, it still meets the protection requirements and has the advantages of good environmental performance and low VOC emissions. Example 4 uses a double-layer glass fiber cloth reinforced structure, achieving a flexural strength of 118.5 MPa, which is approximately 38% higher than the single-layer structure, making it suitable for applications requiring high structural strength.

[0065] Comparative Examples 1 and 3 used styrene-containing unsaturated polyester resins. During the coating process, the styrene monomers in the resin had a severe corrosive effect on the PS foam, causing the foam substrate to collapse and deform, making it impossible to form an effective protective coating. This fully demonstrates that traditional polyester resins are not suitable for the surface treatment of PS foam, while the styrene-free resin used in this invention can effectively solve this problem.

[0066] Comparative Example 2 used styrene-free resin but without fiberglass reinforcement. Although it did not corrode the PS foam, the flexural strength of the coating was only 35.2 MPa, which was more than 50% lower than that of Examples 1 to 3. This indicates that the reinforcement effect of fiberglass cloth is of great significance for improving the structural strength of the coating.

[0067] In the solvent resistance test, the coatings of Examples 1 to 4 were able to effectively protect the PS foam substrate from the erosion of acetone solvent, proving that the styrene-free resin coating has good barrier properties and can prevent organic solvents from penetrating into the PS foam substrate and causing corrosion.

[0068] In summary, the method for preparing a styrene-free resin anti-corrosion coating on PS foam provided by this invention effectively solves the corrosion problem existing in the traditional resin coating process of PS foam. Simultaneously, the reinforcement effect of glass fiber cloth imparts good structural strength to the coating, providing technical support for the widespread application of PS foam in shipbuilding, building insulation, packaging materials, and other fields. This invention encompasses any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this invention. To provide the public with a thorough understanding of this invention, specific details are described in detail in the following preferred embodiments; however, those skilled in the art will fully understand the invention even without these details. Furthermore, to avoid unnecessary misunderstanding of the essence of this invention, well-known methods, processes, procedures, components, and circuits are not described in detail.

[0069] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A styrene-free resin anti-corrosion coating on the surface of PS foam, characterized in that, The anti-corrosion coating comprises, from the inside out, a base coating, a fiberglass cloth reinforcement layer, and a top coating; the base resins of the base coating, the fiberglass cloth reinforcement layer, and the top coating are all styrene-free resins; the styrene-free resins are vinyl ester resins, epoxy resins, or modified acrylic resins; the fiberglass cloth reinforcement layer is formed by impregnating fiberglass cloth with styrene-free resin.

2. A method for preparing a styrene-free resin anti-corrosion coating on the surface of PS foam as described in claim 1, characterized in that, Includes the following steps: S1. PS foam surface pretreatment: Clean the PS foam surface to remove dust, oil and impurities. Wipe the surface with anhydrous ethanol and let it dry before use. S2. Preparation of styrene-free resin: Mix the styrene-free resin main agent with the curing agent, stir evenly, and let stand to defoam; S3. Primer coating: The prepared styrene-free resin is evenly coated onto the surface of PS foam to form a primer coating. S4. Fiberglass cloth laying: With the base coating surface wet, lay the fiberglass cloth flat on the coating surface; S5. Impregnation and paste preparation: Coat the surface of the fiberglass cloth with styrene-free resin, allowing the resin to fully impregnate the fiberglass cloth and eliminate air bubbles; S6. Topcoat coating: After the impregnation layer has initially cured, apply styrene-free resin as a topcoat to the surface of the fiberglass cloth. S7. Curing treatment: Place the coated PS foam in a room temperature environment for curing.

3. The preparation method according to claim 2, characterized in that, In step S2, the mass ratio of the styrene-free resin main agent to the curing agent is 100:1 to 100:3; when the styrene-free resin main agent is a vinyl ester resin, the curing agent is methyl ethyl ketone peroxide or benzoyl peroxide; when the styrene-free resin main agent is an epoxy resin, the curing agent is a modified fatty amine curing agent; when the styrene-free resin main agent is a modified acrylic resin, the curing agent is an isocyanate curing agent.

4. The preparation method according to claim 2, characterized in that, In step S2, when the styrene-free resin main agent is vinyl ester resin, an accelerator is also added. The amount of the accelerator added is 0.5% to 2% of the mass of the resin main agent, and the accelerator is a cobalt naphthenate solution. The standing defoaming time is 5 to 10 minutes.

5. The preparation method according to claim 2, characterized in that, In step S3, the amount of the base coating is 150 to 250 grams per square meter, and the coating thickness is 0.2 to 0.4 millimeters; in step S5, the amount of the impregnation resin is 200 to 350 grams per square meter; in step S6, the amount of the top coating is 100 to 200 grams per square meter, and the coating thickness is 0.15 to 0.3 millimeters.

6. The preparation method according to claim 2, characterized in that, In step S4, the fiberglass cloth is alkali-free fiberglass cloth with a surface density of 200 to 450 grams per square meter; the overlap width of adjacent fiberglass cloths is 20 to 30 millimeters.

7. The preparation method according to claim 2, characterized in that, In step S7, the curing temperature is 20 to 30 degrees Celsius, the curing time is 12 to 24 hours, and the relative humidity of the curing environment is controlled below 70%.

8. The preparation method according to any one of claims 2 to 7, characterized in that, The glass fiber cloth laying and impregnation paste-making operations are repeated once or multiple times between steps S4 and S6 to form a multi-layer glass fiber cloth reinforced composite structure.

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