Outdoor high-performance anti-corrosion wear-resistant coating and preparation method thereof

Abstract

The invention discloses an outdoor high-performance anti-corrosion wear-resistant coating and a preparation method thereof, and belongs to the technical field of protective coatings. According to the coating, water-borne epoxy resin emulsion and water-borne polyurethane dispersion serve as film forming base materials, graphene oxide, flaky mica powder and modified nano silicon dioxide are matched to serve as functional filler, sodium chloride microspheres with the surfaces coated with corrosion inhibitors and a microencapsulated solid lubricant serve as pore forming and self-repairing components as a core, and the self-repairing coating is prepared. The water-based epoxy curing agent and the auxiliary agent are matched. The coating has excellent corrosion resistance and wear resistance and an intelligent self-repairing function, can resist neutral salt mist for over 1500 hours, is extremely low in VOC content, can be cured at room temperature or low temperature, is simple and convenient to construct, is suitable for protection of outdoor science and education equipment, recreation facilities and the like, and can also be expanded to the field of high-end equipment of ships, ocean engineering and the like.

Description

Technical Field

[0001] This invention relates to the field of protective coating technology, and in particular to a water-based outdoor high-performance anti-corrosion and wear-resistant coating with intelligent self-healing function and its preparation method. Background Technology

[0002] With the rapid development of science, education, culture, tourism, sports, and high-end equipment manufacturing, the usage of outdoor science and education equipment, amusement facilities, sports equipment, and metal structural components for ships, high-speed rail, and marine engineering equipment has been increasing year by year. These facilities are exposed to complex outdoor environments for extended periods, continuously facing multiple challenges such as sun and rain, temperature cycles, media corrosion, mechanical friction, and impact, which places extremely high demands on the comprehensive performance of surface protective coatings.

[0003] Currently, for the protection of such outdoor metal facilities, solvent-based anti-corrosion paints or ordinary water-based outdoor coatings are commonly used in civilian applications. These coatings not only have high VOC emissions and poor environmental friendliness, but also suffer from insufficient weather resistance, easy powdering and peeling, and poor abrasion and scratch resistance. During service, the coating is prone to micro-cracks and wear, leading to rapid failure of protective performance. This not only significantly increases the maintenance cycle and operation and maintenance costs of the facilities, but may also cause the substrate to rust due to coating failure, resulting in serious safety hazards.

[0004] In high-end equipment sectors such as shipbuilding, marine engineering, and rail transportation, although specialized heavy-duty anti-corrosion coatings are already in use, these coatings generally suffer from high raw material costs and complex construction processes. They often require multiple coats and high-temperature curing, making them unsuitable for the on-site construction needs of large outdoor facilities and complex structural components. Furthermore, existing high-end heavy-duty anti-corrosion coatings primarily focus on improving coating density, resulting in high internal stress and susceptibility to cracking. Their functions are also relatively limited, generally lacking self-repair capabilities for micro-damage. Once micro-cracks and scratches appear in the coating, corrosive media can quickly penetrate to the substrate surface, causing localized corrosion and placing immense maintenance pressure on long-term service.

[0005] Current research on self-healing coatings largely focuses on the design of single corrosion inhibitor microcapsules, which only passively inhibits the corrosion process and cannot simultaneously address the wear resistance repair after coating wear, making it difficult to meet the dual challenges of corrosion and friction faced by outdoor facilities. Furthermore, existing anti-corrosion coating systems generally strictly control soluble chloride salts such as sodium chloride as harmful impurities because chloride ions have extremely strong penetrating power, easily damaging the passivation film on the metal substrate surface, leading to pitting corrosion and accelerated corrosion. There is currently no mature solution to transform chloride salts into intelligent functional units in anti-corrosion coatings, making it difficult to achieve a low-cost synergy between coating protective performance and self-healing function. Therefore, developing a high-performance outdoor protective coating that combines excellent anti-corrosion and wear resistance, intelligent self-healing function, environmental friendliness, ease of application, and moderate cost has become an urgent technical problem to be solved in this field. Summary of the Invention

[0006] In view of this, the present invention proposes an outdoor high-performance anti-corrosion and wear-resistant coating and its preparation method, aiming to overcome the shortcomings of existing outdoor protective coatings, such as insufficient anti-corrosion and wear-resistant performance, lack of long-term self-healing ability, inability to balance environmental friendliness and construction convenience, and difficulty in balancing comprehensive protective performance and cost, so as to achieve the integrated synergy of anti-corrosion, wear-resistant and self-healing functions of the coating, and meet the protection needs of all scenarios from civilian conventional outdoor facilities to high-end engineering equipment.

[0007] The technical solution of this invention is implemented as follows:

[0008] This invention provides an outdoor high-performance anti-corrosion and wear-resistant coating, comprising a film-forming resin base, functional fillers, core pore-forming and repair components, additives, and a curing agent. The raw materials, by weight, comprise: Film-forming resin base: 30-50 parts of waterborne epoxy resin emulsion, 10-20 parts of waterborne polyurethane dispersion; Functional fillers: 0.5-2 parts graphene oxide, 5-10 parts flaky mica powder, and 3-8 parts modified nano silica; Core pore-forming and repair components: 5-15 parts of sodium chloride microspheres coated with corrosion inhibitor, and 3-10 parts of microencapsulated solid lubricant; Additives: 0.5-1.5 parts wetting and dispersing agent, 0.1-0.5 parts defoamer, 0.2-0.8 parts leveling agent, pH adjuster, wherein the amount of pH adjuster is the amount used to adjust the pH value of the system to 8.0-9.0; Curing agent: water-based epoxy curing agent, wherein the amount of water-based epoxy curing agent added is matched with the epoxy equivalent of the water-based epoxy resin emulsion, and the corresponding weight parts are 8-15 parts.

[0009] In some embodiments, the graphene oxide is a single-layer or few-layer two-dimensional sheet structure with a sheet diameter of 5-20 μm; the flake mica powder is sericite powder with a sheet diameter of 10-30 μm and an aspect ratio ≥60. During the coating curing process, the two can form a labyrinthine physical barrier through planar orientation, significantly extending the penetration path of corrosive media such as water, oxygen, and chloride ions within the coating, fundamentally reducing the probability of corrosive media reaching the substrate surface, and providing basic long-term physical protection for the coating; at the same time, the two-dimensional sheet structure can effectively disperse the external impact on the coating, improve the coating's crack resistance and impact resistance, and form a synergistic mechanical reinforcement effect with the resin matrix.

[0010] In some embodiments, the sodium chloride microspheres coated with corrosion inhibitors have sodium chloride as their core, with a zinc stearate hydrophobic isolation layer on the surface of the core. The zinc stearate hydrophobic isolation layer is loaded with corrosion inhibitors. Through the design of the zinc stearate hydrophobic isolation layer, the aqueous environment can be isolated from the sodium chloride core when the coating is intact, preventing premature dissolution and release of chloride ions from the sodium chloride, while providing stable loading sites for the corrosion inhibitor. Only when microcracks appear in the coating and external moisture penetrates, the hydrophobic isolation layer is wetted and dissolved, and the sodium chloride core and corrosion inhibitor are released simultaneously. This achieves damage-directed triggering of the self-repair function, fundamentally solving the corrosion risk caused by premature release of chloride ions within the coating, and overturning the traditional strict restriction of soluble salts such as sodium chloride in anti-corrosion coatings.

[0011] In some embodiments, the corrosion inhibitor is sodium molybdate or benzotriazole. Sodium molybdate is selected as an anodic corrosion inhibitor, which can rapidly form a dense Fe-Mo-O passivation film on the metal substrate surface, blocking the anodic reaction process of electrochemical corrosion. Benzotriazole is an adsorption-type corrosion inhibitor, which can form a monomolecular-level protective film on the metal surface through chemical adsorption, preferentially occupying the active reaction sites on the metal surface. Both can compete with the simultaneously released chloride ions for adsorption, completely offsetting the corrosion risk of chloride ions and ensuring that no additional corrosion risks are caused during the self-repair process.

[0012] In some embodiments, the microencapsulated solid lubricant uses polyurea or gelatin-gum arabic as the wall material and molybdenum disulfide or graphite powder as the core material, prepared by in-situ polymerization or complex coagulation. The microcapsule encapsulation design prevents premature precipitation or failure of the solid lubricant during coating preparation and storage, ensuring its stable dispersion within the coating. When the coating is subjected to friction or scratching forces, the microcapsule walls rupture under shear force, releasing the internal solid lubricant core material, which can quickly fill the worn areas of the coating, continuously reducing the coefficient of friction on the coating surface and achieving passive self-repair of the coating's wear resistance. Its function complements the anti-corrosion self-repair of sodium chloride microspheres, constructing a dual self-repair protection system of "active corrosion repair + passive wear repair." The synergy of these two systems enables full-dimensional repair of coating micro-damage, completely solving the pain point of traditional coatings where micro-damage quickly leads to protective failure.

[0013] In some embodiments, the modified nano-silica is nano-silica with a surface hydrophobic modification by a silane coupling agent, and a particle size of 20-100 nm. The silane coupling agent-modified nano-silica can achieve uniform dispersion in aqueous resin systems, avoiding nanoparticle agglomeration and failure. Its nanoscale particle size can fill the gaps between the resin matrix and the sheet filler, improving the density and cross-linking degree of the coating, while simultaneously enhancing the surface hardness and scratch resistance of the coating. Together with the sheet structure of graphene oxide and flake mica powder, it forms a "rigid-flexible" mechanical reinforcement system, further optimizing the overall mechanical properties of the coating.

[0014] In some embodiments, the waterborne epoxy resin emulsion has a solid content of 48%-52% and an epoxy equivalent of 190-210 g / eq; the waterborne polyurethane dispersion has a solid content of 33%-37%. Using a waterborne epoxy resin emulsion within this parameter range ensures excellent substrate adhesion, chemical resistance, and corrosion-resistant density after coating curing, providing a basic protective framework for the coating. Matching the waterborne polyurethane dispersion with the corresponding solid content allows it to form an interpenetrating polymer network with the epoxy resin during curing, compensating for the brittleness and poor weather resistance of a single epoxy resin, achieving a balance between coating hardness and flexibility, and significantly improving the coating's impact resistance, crack resistance, and outdoor weather life. The amount of waterborne epoxy curing agent added must be precisely matched with the epoxy equivalent of the waterborne epoxy resin to ensure that the epoxy resin can be fully cured under room temperature / low temperature conditions, avoiding problems such as insufficient coating density and reduced protective performance caused by incomplete curing. For waterborne epoxy resin emulsions with an epoxy equivalent of 190-210 g / eq, the appropriate curing agent weight parts are 8-15 parts.

[0015] In some embodiments, the sodium chloride microspheres coated with corrosion inhibitor have a particle size of 30-100 μm, and the microencapsulated solid lubricant has a particle size of 10-50 μm. Controlling the particle size range of the sodium chloride microspheres, and ensuring that their particle size does not exceed 1 / 2 of the dry film thickness of the coating, ensures that they form uniformly distributed isolated micropores within the coating, preventing the micropores from interconnecting and forming channels for the corrosive medium to penetrate. Simultaneously, the micropores can effectively buffer the internal stress generated by temperature changes and external impacts in the coating, reducing the risk of coating cracking. Matching the microencapsulated solid lubricant to the corresponding particle size ensures its uniform dispersion within the coating, enabling a rapid response when friction occurs and achieving a stable wear-resistant self-repairing effect.

[0016] In some embodiments, the pH adjuster is an organic amine pH adjuster, selected from at least one of 2-amino-2-methyl-1-propanol and dimethylethanolamine; the pH value of the system needs to be precisely adjusted to 8.0-9.0. This weakly alkaline range can ensure the storage stability of the waterborne epoxy resin emulsion and waterborne polyurethane dispersion, avoid demulsification and gelation problems during storage, and at the same time control the reaction rate of the waterborne epoxy curing agent to avoid problems such as too short construction period due to too fast curing and film formation defects due to too slow curing.

[0017] In some embodiments, the present invention also provides a method for preparing the above-mentioned high-performance outdoor anti-corrosion and wear-resistant coating, specifically including the following steps: S1 Premixing: Under stirring, wetting and dispersing agent, defoamer, and 1 / 2 of the formulation amount of leveling agent are added to deionized water in sequence, and stirred evenly to obtain a premixed liquid; the leveling agent is added in two batches. The leveling agent added in the first batch can assist the wetting and dispersion of inorganic fillers, avoid the leveling agent being adsorbed and ineffective by the fillers when added at one time, and ensure the dispersion effect of the fillers. S2 Filler Dispersion: Slowly add graphene oxide, flake mica powder, and modified nano-silica to the premix obtained in S1, and disperse at high speed until the system fineness is ≤30μm to obtain a filler dispersion; S3 Resin Mixing: Reduce the stirring speed to below 300rpm, and add waterborne epoxy resin emulsion and waterborne polyurethane dispersion to the filler dispersion obtained in S2 in sequence, and stir evenly to obtain a resin base liquid; S4 Functional Component Addition: Add sodium chloride microspheres with surface-coated corrosion inhibitor and microencapsulated solid lubricant to the resin base liquid obtained in S3, and stir at a speed of 100-300rpm until evenly dispersed to avoid high-speed shearing damaging the coating / capsule structure of the components; S5 Paint Adjustment: Adjust the pH value of the system to 8.0-9.0 with a pH adjuster, add the remaining leveling agent, and stir evenly to obtain a coating base; The leveling agent added later can fully retain its surface activity, optimize the leveling properties and film surface effect of the coating, and avoid defects such as pinholes and orange peel in the coating. S6 Curing and Application: Add water-based epoxy curing agent to the coating base obtained from S5, stir evenly, and cure for 20-30 minutes. Then apply it to the pretreated substrate and cure at room temperature or below 80°C to form a film. Through the process design of step-by-step feeding and graded speed control, the inorganic filler is fully dispersed first, ensuring that the labyrinth barrier effect of the lamellar filler is fully utilized. Then, the resin mixing and functional component addition are completed by low-speed stirring, which can completely avoid the damage of high-speed shear to the hydrophobic isolation layer of sodium chloride microspheres and microcapsule walls, ensuring the structural integrity of the core self-healing components. The curing process can ensure the initial pre-reaction of the curing agent and epoxy resin, improving the crosslinking density and performance stability of the coating after curing.

[0018] In some embodiments, in step S6, the application method is spraying or brushing; the substrate is a metal substrate that has been sandblasted to Sa2.5 grade, and the dry film thickness of the coating after curing is controlled to be 100-200μm. It is compatible with both conventional spraying and brushing methods, adaptable to the on-site construction needs of large outdoor facilities and complex structural components, and requires no special construction equipment. Controlling the pretreatment level of the substrate and the dry film thickness of the coating ensures excellent adhesion between the coating and the substrate, while providing sufficient bearing space for the core functional components, ensuring the long-term protective performance of the coating.

[0019] In some embodiments, the present invention also provides the application of the above-mentioned high-performance outdoor anti-corrosion and wear-resistant coating in the long-term protection of metal surfaces of outdoor scientific and educational equipment, amusement facilities, and sports equipment. Metal facilities in such scenarios are exposed to complex outdoor environments for extended periods and face frequent human friction and impacts, placing high demands on the coating's anti-corrosion, wear-resistant, and crack-resistant properties. The coating of the present invention perfectly meets the protection needs of such scenarios, significantly reducing the maintenance cycle and cost of the facilities and improving their safety.

[0020] In some embodiments, the present invention also provides the application of the above-mentioned high-performance outdoor anti-corrosion and wear-resistant coating in the long-term protection of metal surfaces of ships, high-speed railways, and marine engineering equipment. These high-end equipment operate in extreme outdoor environments characterized by high humidity, high salinity, and strong corrosion, placing stringent requirements on the long-term protective performance of the coating. The coating of the present invention, through the synergy of multi-level barrier protection and dual self-healing functions, can meet the long-term protection needs under extreme corrosive environments, achieving domestic substitution.

[0021] The present invention has the following advantages over the prior art: This invention, through reverse engineering, transforms sodium chloride, a component strictly avoided in traditional anti-corrosion coatings, into an intelligent functional unit integrating pore formation, corrosion inhibitor loading, and self-healing triggering. Combined with microencapsulated solid lubricant, it constructs a dual self-healing system for both corrosion protection and wear resistance, completely solving the industry pain points of traditional outdoor protective coatings that cannot simultaneously achieve both corrosion resistance and wear resistance, and lack long-term self-healing capabilities. Through the synergistic effect of a waterborne epoxy-polyurethane interpenetrating network film-forming system and multi-layered lamellar barrier fillers, a balance between coating hardness and flexibility is achieved, significantly improving the coating's basic protective performance and outdoor weather resistance life. Simultaneously, using water as the dispersion medium, it possesses excellent environmental friendliness. The coating preparation process of this invention is simple and controllable, requiring no special production or construction equipment, and is compatible with both room temperature and low temperature curing. It is suitable for all scenarios of protection, from conventional outdoor science and education recreational facilities to high-end marine engineering and rail transit equipment. While ensuring high-performance protection, it achieves cost control, possessing strong industrialization promotion value and market application prospects. Detailed Implementation

[0022] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0023] All raw materials used in the examples and comparative examples in this section are commercially available industrial-grade or analytical-grade products, which can be obtained by those skilled in the art through conventional commercial channels; unless otherwise specified, the environmental conditions for all preparation and testing processes are a temperature of 23±2℃ and a relative humidity of 50±5%; all performance tests are performed in accordance with current effective national standards to ensure that the test results are reproducible and verifiable.

[0024] Raw material specifications The waterborne epoxy resin emulsion used was Baling Petrochemical CYDW-100 type, with a solid content of 50±2% and an epoxy equivalent of 200±10 g / eq; the waterborne polyurethane dispersion used was Covestro Bayhydrol UH 2593 / 1 type, with a solid content of 35±2% and a hydroxyl content of 1.2%; the graphene oxide used was an aqueous dispersion from Changzhou Sixth Element with a monolayer rate ≥90% and a sheet diameter of 5-20 μm, with a solid content of 2%; the flake mica powder used was 325 mesh sericite powder from Chuzhou Gree Mining with an aspect ratio ≥80 and a sheet diameter of 10-30 μm; the modified nano silica used was a product from Xuancheng Jingrui modified with silane coupling agent KH560, with a particle size of 50±20 nm and a solid content of 99%; the sodium chloride was an analytical grade reagent from Sinopharm Group, with particles of 50-100 μm used after sieving; and the zinc stearate was 2000 mesh industrial grade from Hebei Sainuo New Materials. Grade A products; sodium molybdate and benzotriazole are analytical grade reagents produced by Sinopharm Group, with a purity ≥99%; wetting and dispersing agent is BYK-190 from BYK Chemical, defoamer is BYK-024 from BYK Chemical, and leveling agent is BYK-346 from BYK Chemical; pH adjuster is AMP-95 (2-amino-2-methyl-1-propanol) from Dow Chemical, with a purity ≥95%; water-based epoxy curing agent is CYDH-811 from Baling Petrochemical, a modified aliphatic amine with an active hydrogen equivalent of 210±10 g / eq; the test substrate is a national standard Q235 cold-rolled steel plate with dimensions of 150mm×70mm×2mm.

[0025] The equipment used for preparation included a Shanghai Modern Environment SFJ-400 high-speed disperser with a speed range of 0-3000 rpm; a Sartorius BSA224S electronic balance with an accuracy of 0.1 mg; and a Shanghai Pushen SS adjustable paint film applicator. The equipment used for testing included a Shanghai Linpin LRHS-108-RY salt spray test chamber, a Shanghai Modern Environment JM-IV Taber abrasion tester, a Shanghai Pushen QFH cross-cut tester (1 mm × 1 mm grid spacing), and a Shanghai Pushen QTX paint film flexibility tester.

[0026] All Q235 steel plates used for testing were sandblasted to Sa2.5 grade as specified in GB / T 8923.1-2011, with surface roughness controlled at Ra=60±20μm. After sandblasting, the steel plate surface was cleaned three times with anhydrous ethanol to remove surface oil and dust, and the coating operation was completed within 2 hours after drying.

[0027] The core quality control indicators of all preparation embodiments of this invention were tested using the following standardized methods, and all testing environments were at a temperature of 23±2℃ and a relative humidity of 50±5%. 1. Coating rate of zinc stearate on sodium chloride microspheres: This was determined using anhydrous ethanol extraction. 10.000 g of the coated microspheres were accurately weighed and placed in a 250 mL stoppered conical flask. 100 mL of 60 °C hot anhydrous ethanol was added, and the mixture was ultrasonically extracted at this temperature for 5 minutes. The mixture was then rapidly filtered through quantitative filter paper, and the residue was washed three times with hot anhydrous ethanol. The filtrate and washings were combined, and the mixture was rotary evaporated to constant weight. The mass of extracted zinc stearate was then weighed. The coating rate was calculated using the formula: Coating rate = (Actual extracted zinc stearate mass / Theoretical added zinc stearate mass) × 100%.

[0028] 2. Corrosion Inhibitor Loading: The loading was determined using UV-Vis spectrophotometry. For sodium molybdate, a standard solution was prepared using deionized water as the solvent, and a standard curve was plotted at the characteristic absorption wavelength of 230 nm. 2.000 g of the microspheres to be tested were accurately weighed, immersed in 100 mL of deionized water, and sonicated until completely dissolved. The absorbance was measured using a UV spectrophotometer, and the sodium molybdate loading was calculated by referring to the standard curve. For benzotriazole, anhydrous ethanol was used as the solvent, and a standard curve was plotted at the characteristic absorption wavelength of 259 nm. The benzotriazole loading was calculated using the same method. The loading formula is: Corrosion Inhibitor Loading = (Actual Corrosion Inhibitor Mass / Total Mass of Microspheres to be Tested) × 100%.

[0029] 3. Moisture content: Determined according to GB / T 6283-2008 "Determination of moisture content in chemical products - Karl Fischer method", using a Karl Fischer moisture analyzer for direct determination.

[0030] 4. Microcapsule particle size distribution: The volume average particle size and particle size distribution range of the microcapsules were determined according to GB / T 19077-2016 "Particle size analysis by laser diffraction". A wet laser particle size analyzer was used with deionized water as the dispersion medium.

[0031] 5. Encapsulation efficiency of microcapsule core material: This was determined using Soxhlet extraction. 5.000 g of the microcapsules to be tested were accurately weighed, wrapped in quantitative filter paper, and placed in a Soxhlet extractor. Ethyl acetate was used as the extraction solvent, and the mixture was refluxed at 80℃ for 6 hours to extract the core material free on the surface of the microcapsules. After extraction, the extract was rotary evaporated to constant weight, and the mass of the free core material was weighed. The encapsulation efficiency was calculated using the formula: Encapsulation efficiency = (Theoretical core material added mass - Free core material mass) / Theoretical core material added mass × 100%.

[0032] 6. Microcapsule breakage rate: This was tested under simulated stirring conditions during the preparation of the coating of this invention. 10.000 g of the microcapsules to be tested were accurately weighed and added to 200 mL of deionized water. The mixture was placed in a high-speed disperser and stirred at 300 rpm for 30 minutes. After stirring, the suspension was taken, and the total mass of the free core material was determined using the Soxhlet extraction method described above. The initial mass of the free core material before stirring was subtracted to obtain the mass of the core material released by the breakage. The breakage rate was calculated as follows: Breakage rate = (Mass of newly released free core material after stirring / Theoretical total core material mass) × 100%.

[0033] Preparation Example 1: Sodium chloride microspheres coated with sodium molybdate Step 1: Raw material pretreatment. Sodium chloride powder is sieved through a standard sieve to collect particles with a diameter of 50-100μm. The particles are then dried in a vacuum drying oven at 105℃ for 2 hours. After drying, the particles are placed in a desiccator and cooled to room temperature for later use.

[0034] Step 2: Preparation of hydrophobic coating layer. Take 100 parts by weight of dried sodium chloride powder and 2 parts by weight of zinc stearate, add them to a high-speed mixer, set the speed to 3000 rpm and mix for 15 minutes to make the zinc stearate uniformly adhere to the surface of sodium chloride particles to form a continuous hydrophobic coating layer. After discharge, pass through a 200-mesh sieve to remove agglomerated particles and obtain hydrophobically coated sodium chloride microspheres.

[0035] Step 3: Corrosion inhibitor loading. The hydrophobically coated sodium chloride microspheres were immersed in a 10% (w / w) sodium molybdate aqueous solution at a constant temperature of 25°C for 30 minutes. After immersion, the microspheres were filtered and separated. The filter cake was dried in a vacuum drying oven at 60°C for 4 hours. After discharge, the microspheres were passed through a 200-mesh sieve to obtain sodium chloride microspheres coated with sodium molybdate. According to the above general methods, the microspheres prepared in this embodiment had a coating rate ≥96%, a corrosion inhibitor loading ≥2.5%, and a moisture content ≤0.3%.

[0036] Preparation Example 2: Sodium chloride microspheres coated with benzotriazole Step 1: Raw material pretreatment, which is completely consistent with Step 1 of Preparation Example 1.

[0037] Step 2: Preparation of the hydrophobic coating layer, which is completely consistent with Step 2 of Preparation Example 1.

[0038] Step 3: Corrosion inhibitor loading. The hydrophobically coated sodium chloride microspheres were immersed in a 5% (w / w) benzotriazole ethanol solution for 30 minutes at a constant temperature of 25°C. After immersion, the microspheres were filtered and separated. The filter cake was dried in a vacuum drying oven at 60°C for 4 hours. After discharge, the microspheres were passed through a 200-mesh sieve to obtain sodium chloride microspheres coated with benzotriazole. According to the above general methods, the microspheres prepared in this example had a coating rate ≥95%, a corrosion inhibitor loading ≥1.8%, and a moisture content ≤0.3%.

[0039] Preparation Example 3: Polyurea Microencapsulated Molybdenum Disulfide Solid Lubricant Step 1: Oil phase preparation. Take 10 parts by weight of molybdenum disulfide powder and 5 parts by weight of isophorone diisocyanate, add them to 50 parts by weight of ethyl acetate, and disperse at high speed of 2000 rpm for 30 minutes to obtain a uniformly dispersed oil phase system.

[0040] Step 2: Aqueous phase preparation: Take 2 parts by weight of sodium dodecylbenzenesulfonate, add it to 200 parts by weight of deionized water, stir at room temperature until completely dissolved, and obtain an emulsifier aqueous solution with a mass concentration of 1% as the aqueous phase.

[0041] Step 3: Emulsification treatment. The oil phase is slowly dripped into the aqueous phase, and high-speed emulsification is carried out at 3000 rpm for 30 minutes to obtain a stable oil-in-water emulsion.

[0042] Step 4: In-situ polymerization reaction. The emulsion is heated to 60°C and kept at a constant temperature. 10 parts by weight of diethylenetriamine are slowly added dropwise. After the addition is completed, the mixture is stirred at a constant temperature for 3 hours to complete the polymerization and curing of the polyurea wall material.

[0043] Step 5: Post-processing. After the reaction, the mixture is filtered and separated. The filter cake is washed three times with deionized water. The washed filter cake is then dried in a vacuum drying oven at 40℃ for 6 hours. After discharge, it is passed through a 300-mesh sieve to obtain polyurea microencapsulated molybdenum disulfide solid lubricant. According to the general methods described above, the microcapsule particle size prepared in this embodiment is 20-40 μm, the core material encapsulation rate is ≥85%, and the breakage rate after stirring at 300 rpm for 30 minutes is ≤5%.

[0044] Preparation Example 4: Gelatin-Gum Arabidopsis Microencapsulated Graphite Powder Solid Lubricant Step 1: Preparation of wall material solutions. Prepare 5% (w / w) gelatin aqueous solution and 5% (w / w) gum arabic aqueous solution respectively, and keep them in a constant temperature water bath at 40℃ for later use.

[0045] Step 2: Core material dispersion. Take 10 parts by weight of graphite powder and add it to 100 parts by weight of gelatin aqueous solution after heat preservation. Disperse at 2000 rpm for 20 minutes under constant temperature of 40℃ to obtain a uniformly dispersed mixture of graphite powder.

[0046] Step 3: Complex coagulation reaction. Add 100 parts by weight of the heat-insulated gum arabic aqueous solution to the mixture, stir evenly at 40°C, adjust the pH of the system to 4.0 with a 10% acetic acid solution, and continue stirring at a constant temperature for 30 minutes to complete the complex coagulation reaction and form the microcapsule wall.

[0047] Step 4: Curing treatment. Cool the system to below 10°C, add 5% glutaraldehyde aqueous solution, and stir continuously at a constant temperature for 2 hours to complete the cross-linking and curing of the microcapsules.

[0048] Step 5: Post-processing. After the reaction is complete, filter and separate the mixture. Wash the filter cake with deionized water until the filtrate is neutral. Place the washed filter cake in a vacuum drying oven at 40℃ and dry for 6 hours. After discharge, pass the material through a 300-mesh sieve to obtain gelatin-gum arabic microcapsule graphite powder solid lubricant. According to the above general methods, the microcapsule particle size prepared in this example is 20-40 μm, the core material encapsulation rate is ≥80%, and the breakage rate after stirring at 300 rpm for 30 minutes is ≤6%.

[0049] Example 1 (Lower limit of formulation) The raw materials in this embodiment, by weight, are as follows: 30 parts of waterborne epoxy resin emulsion, 10 parts of waterborne polyurethane dispersion, 0.5 parts of graphene oxide, 5 parts of flake mica powder, 3 parts of modified nano-silica, 10 parts of sodium chloride microspheres with sodium molybdate surface coating prepared in Example 1, 5 parts of polyurea microencapsulated molybdenum disulfide solid lubricant prepared in Example 3, 1 part of wetting and dispersing agent, 0.3 parts of defoamer, 0.5 parts of leveling agent, 8 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0050] The preparation steps are as follows: Step 1: Premixing. While stirring at 200 rpm, add the wetting and dispersing agent, defoamer, and 1 / 2 of the formula amount of leveling agent to the metered deionized water in sequence. Continue stirring for 10 minutes until the system is homogeneous to obtain the premixed solution.

[0051] Step 2: Filler dispersion. Slowly add graphene oxide, flake mica powder, and modified nano silica to the premixed solution. Increase the rotation speed to 1500 rpm and disperse at high speed for 25 minutes. Stop the dispersion after the fineness of the system is ≤30μm to obtain the filler dispersion.

[0052] Step 3: Resin mixing. Reduce the stirring speed to 200 rpm, add waterborne epoxy resin emulsion and waterborne polyurethane dispersion to the filler dispersion in sequence, and continue stirring for 15 minutes until the system is uniform, without layering or agglomeration, to obtain the resin base liquid.

[0053] Step 4: Add functional components. Add sodium chloride microspheres coated with sodium molybdate and polyurea microencapsulated molybdenum disulfide solid lubricant to the resin base liquid. Stir continuously at 200 rpm for 10 minutes until the components are evenly dispersed and there is no obvious agglomeration. Avoid high-speed shearing throughout the process.

[0054] Step 5: Mix the paint. Use a pH adjuster to precisely adjust the pH value of the system to 8.5. Add the remaining 1 / 2 of the formula amount of leveling agent and stir at 200 rpm for 5 minutes until uniform to obtain the paint base.

[0055] Step 6: Curing and application. Add the measured amount of water-based epoxy curing agent to the forward coating base, stir evenly, and cure for 25 minutes. Apply the curing agent to the pretreated Q235 steel plate by air spraying, control the dry film thickness to be 120±5μm, and perform performance testing after curing at room temperature for 7 days.

[0056] Example 2 (Recipe Intermediate Value) The raw materials in this embodiment, by weight, are as follows: 40 parts of waterborne epoxy resin emulsion, 15 parts of waterborne polyurethane dispersion, 1 part of graphene oxide, 8 parts of flake mica powder, 5 parts of modified nano-silica, 10 parts of sodium chloride microspheres with sodium molybdate surface coating prepared in Example 1, 5 parts of polyurea microencapsulated molybdenum disulfide solid lubricant prepared in Example 3, 1 part of wetting and dispersing agent, 0.3 parts of defoamer, 0.5 parts of leveling agent, 12 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0057] The preparation steps are completely consistent with steps 1 to 6 of Example 1.

[0058] Example 3 (Upper Limit of Formula) The raw materials in this embodiment, by weight, are as follows: 50 parts of waterborne epoxy resin emulsion, 20 parts of waterborne polyurethane dispersion, 2 parts of graphene oxide, 10 parts of flake mica powder, 8 parts of modified nano-silica, 10 parts of sodium chloride microspheres with sodium molybdate surface coating prepared in Example 1, 5 parts of polyurea microencapsulated molybdenum disulfide solid lubricant prepared in Example 3, 1.5 parts of wetting and dispersing agent, 0.5 parts of defoamer, 0.8 parts of leveling agent, 15 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0059] The preparation steps are completely consistent with steps 1 to 6 of Example 1.

[0060] Example 4 (Lower limit of sodium chloride microspheres) The raw materials in this embodiment, by weight, are as follows: 40 parts of waterborne epoxy resin emulsion, 15 parts of waterborne polyurethane dispersion, 1 part of graphene oxide, 8 parts of flake mica powder, 5 parts of modified nano-silica, 5 parts of sodium chloride microspheres with sodium molybdate surface coating prepared in Example 1, 5 parts of polyurea microencapsulated molybdenum disulfide solid lubricant prepared in Example 3, 0.5 parts of wetting and dispersing agent, 0.1 parts of defoamer, 0.2 parts of leveling agent, 10 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0061] The preparation steps are completely consistent with steps 1 to 6 of Example 1, except that in step 5, the pH value of the system is precisely adjusted to 8.0 using a pH adjuster.

[0062] Example 5 (Upper Limit of Sodium Chloride Microspheres) The raw materials in this embodiment, by weight, are as follows: 40 parts of waterborne epoxy resin emulsion, 15 parts of waterborne polyurethane dispersion, 1 part of graphene oxide, 8 parts of flake mica powder, 5 parts of modified nano-silica, 15 parts of sodium chloride microspheres with sodium molybdate surface coating prepared in Example 1, 5 parts of polyurea microencapsulated molybdenum disulfide solid lubricant prepared in Example 3, 1.5 parts of wetting and dispersing agent, 0.5 parts of defoamer, 0.8 parts of leveling agent, 14 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0063] The preparation steps are completely consistent with steps 1 to 6 of Example 1, except that in step 5, the pH value of the system is precisely adjusted to 9.0 using a pH adjuster.

[0064] Example 6 (Alternative Corrosion Inhibitor) The raw materials in this embodiment, by weight, are as follows: 40 parts of waterborne epoxy resin emulsion, 15 parts of waterborne polyurethane dispersion, 1 part of graphene oxide, 8 parts of flake mica powder, 5 parts of modified nano-silica, 10 parts of sodium chloride microspheres coated with benzotriazole obtained in Preparation Example 2, 5 parts of polyurea microencapsulated molybdenum disulfide solid lubricant obtained in Preparation Example 3, 1 part of wetting and dispersing agent, 0.3 parts of defoamer, 0.5 parts of leveling agent, 12 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0065] The preparation steps are completely consistent with steps 1 to 6 of Example 1.

[0066] Example 7 (Lower limit value of microencapsulated lubricant) The raw materials in this embodiment, by weight, are as follows: 40 parts of waterborne epoxy resin emulsion, 15 parts of waterborne polyurethane dispersion, 1 part of graphene oxide, 8 parts of flake mica powder, 5 parts of modified nano-silica, 10 parts of sodium chloride microspheres with sodium molybdate surface coating prepared in Example 1, 3 parts of polyurea microencapsulated molybdenum disulfide solid lubricant prepared in Example 3, 1 part of wetting and dispersing agent, 0.3 parts of defoamer, 0.5 parts of leveling agent, 12 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0067] The preparation steps are completely consistent with steps 1 to 6 of Example 1.

[0068] Example 8 (Upper Limits and Alternatives for Microencapsulated Lubricants) The raw materials in this embodiment, by weight, are as follows: 40 parts of waterborne epoxy resin emulsion, 15 parts of waterborne polyurethane dispersion, 1 part of graphene oxide, 8 parts of flake mica powder, 5 parts of modified nano-silica, 10 parts of sodium chloride microspheres with sodium molybdate surface coating obtained in Preparation Example 1, 10 parts of gelatin-gum arabic microcapsule graphite powder solid lubricant obtained in Preparation Example 4, 1 part of wetting and dispersing agent, 0.3 parts of defoamer, 0.5 parts of leveling agent, 12 parts of waterborne epoxy curing agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0069] The preparation steps are completely consistent with steps 1 to 6 of Example 1.

[0070] Comparative Example 1 (closest to existing technology) This comparative example uses a commercially available conventional waterborne epoxy heavy-duty anti-corrosion coating formula. The raw materials, by weight, are: 40 parts waterborne epoxy resin emulsion, 12 parts waterborne epoxy curing agent, 15 parts barium sulfate, 10 parts talc, 5 parts titanium dioxide, 1 part wetting and dispersing agent, 0.3 parts defoamer, 0.5 parts leveling agent, appropriate amount of pH adjuster, and deionized water to make up to a total weight of 100 parts.

[0071] The preparation steps are as follows: Step 1: Premixing. While stirring at 200 rpm, add the wetting and dispersing agent, defoamer, and leveling agent to the metered deionized water in sequence, and continue stirring for 10 minutes until the system is homogeneous to obtain the premixed solution.

[0072] Step 2: Dispersing the filler. Slowly add barium sulfate, talc, and titanium dioxide to the premixed solution. Increase the rotation speed to 1500 rpm and disperse at high speed for 25 minutes. Stop the dispersion after the fineness of the system is ≤30μm to obtain the filler dispersion.

[0073] Step 3: Resin mixing. Reduce the stirring speed to 200 rpm, add water-based epoxy resin emulsion to the filler dispersion, and continue stirring for 15 minutes until the system is homogeneous to obtain the resin base liquid.

[0074] Step 4: Mix the paint. Adjust the pH of the system to 8.5 with a pH adjuster and stir well to obtain the paint base.

[0075] Step 5: Curing and application. Add the measured amount of water-based epoxy curing agent to the forward coating base, stir evenly, and cure for 25 minutes. Apply the curing agent to the pretreated Q235 steel plate by air spraying, control the dry film thickness to be 120±5μm, and perform performance testing after curing at room temperature for 7 days.

[0076] Comparative Example 2 (Control without sodium chloride microspheres) The only difference between this comparative example and the baseline example 2 is that an equal amount of barium sulfate is used to replace the sodium chloride microspheres coated with sodium molybdate. The rest of the raw material formulation and preparation steps are completely consistent with example 2.

[0077] Comparative Example 3 (Control with missing microencapsulated lubricant) The only difference between this comparative example and the baseline example 2 is that an equal amount of unmicroencapsulated molybdenum disulfide powder is used to replace the polyurea microencapsulated molybdenum disulfide solid lubricant. The rest of the raw material formulation and preparation steps are completely consistent with example 2.

[0078] Comparative Example 4 (Sodium chloride microspheres without hydrophobic coating as control) The only difference between this comparative example and the baseline example 2 is that the sodium chloride microspheres used are sodium chloride microspheres without a zinc stearate hydrophobic coating layer and only adsorb sodium molybdate on the surface. The other raw material formulations and preparation steps are completely consistent with those of example 2. The preparation steps of the sodium chloride microspheres without hydrophobic coating layer are as follows: take the sieved sodium chloride microspheres, immerse them directly in a 10% sodium molybdate aqueous solution for 30 minutes, filter and dry them before use.

[0079] Comparative Example 5 (Correction of Violations in Core Process Parameters) The only difference between this comparative example and the baseline example 2 is that when adding the functional component in step 4, high-speed stirring at 1500 rpm was used for dispersion. The rest of the raw material formulation and preparation steps are completely consistent with example 2.

[0080] Comparative Example 6 (pH value deviating from the specified range control) The only difference between this comparative example and the baseline example 2 is that in step 5, when preparing the paint, the pH value of the system is adjusted to 7.0 using a pH adjuster. The rest of the raw material formulation and preparation steps are completely consistent with example 2.

[0081] Coating performance verification method All performance tests in this section strictly follow current and valid national standards. The test steps are repeatable and verifiable. All test samples are standard samples cured at room temperature for 7 days.

[0082] 1. Neutral Salt Spray Resistance Test The test was conducted according to GB / T 1771-2007 "Determination of resistance to neutral salt spray in paints and varnishes", and the test steps are as follows: Step 1: Sample preparation. Take two parallel test samples. One is a complete sample without scratches. The other is scratched through the coating to the substrate with a special scratching knife. The scratch length is 50mm and the width is 0.3±0.05mm. Step 2: Salt spray test chamber debugging. Prepare a 5% sodium chloride aqueous solution, adjust the pH value of the solution to 6.5-7.2, set the test chamber temperature to 35±2℃, continuous spray mode, and control the sedimentation rate to 1-2mL / 80cm²·h. Step 3: Testing and Recording. Place the sample in the test chamber with the scratched surface at an angle of 15°-30° to the vertical direction. Conduct continuous spray testing and record the time when blistering and corrosion first appear on the unscratched sample. After 1000 hours of testing, measure the unilateral corrosion width of the scratched sample.

[0083] 2. Abrasion resistance test The test was conducted according to GB / T 1768-2006 "Determination of Abrasion Resistance of Paints and Varnishes - Rotating Rubber Grinding Wheel Method", and the test steps are as follows: Step 1: Sample preparation. Take a circular test sample with a diameter of 100 mm, the dry film thickness of the coating is 120±5 μm, and cure at room temperature for 7 days. Step 2: Equipment debugging, install CS-10 rubber grinding wheel, configure 1000g standard weight load, and calibrate the equipment zero point; Step 3: Testing and Recording. Fix the sample on the test bench, start the equipment and test for 1000 revolutions. After the test, clean the sample surface with anhydrous ethanol, weigh the sample before and after the test with an electronic balance with an accuracy of 0.1 mg, and calculate the weight loss.

[0084] 3. Adhesion Test The test shall be conducted in accordance with GB / T 9286-1998 "Cross-cut test for paint and varnish films", and the test procedure is as follows: Step 1: Sample preparation. Take a standard test sample with a dry film thickness of 120±5μm and cure at room temperature for 7 days. Step 2: Grid cutting operation. Using a grid cutter with a grid spacing of 1mm×1mm, make 6 parallel cutting lines on the coating surface, and then make 6 parallel cutting lines perpendicularly to form a grid. The cutting depth penetrates the coating to the substrate surface. Step 3: Rating. Use a soft brush to brush back and forth 5 times along the diagonal of the grid. Use a magnifying glass to observe the coating peeling in the grid area. Rating according to the standard from 0 to 5, with 0 being the best.

[0085] 4. Flexibility Test The test shall be performed in accordance with GB / T 1731-1993 "Determination of Flexibility of Paint Films", and the test steps are as follows: Step 1: Sample preparation. Take a 120mm×25mm×0.3mm tinplate sample, coat it, and control the dry film thickness to 120±5μm. Cur at room temperature for 7 days. Step 2: Testing operation. Place the sample on the flexibility tester and bend it 180° around shafts with diameters of 1mm, 2mm, 3mm, 4mm and 5mm in sequence. The bending time should be controlled to be 2-3 seconds. Step 3: Rating. Observe the coating after bending with a 4x magnifying glass and record the smallest shaft diameter where the coating has no mesh, cracks, or peeling.

[0086] 5. Storage stability test The test shall be conducted in accordance with GB / T 6753.3-1986 "Test Method for Storage Stability of Coatings", and the test steps are as follows: Step 1: Sample preparation. Take 500 mL of paint base (without hardener), put it into a sealed wide-mouth bottle, and seal it. Step 2: Constant temperature storage. Place the sealed sample in a 50℃ constant temperature drying oven and store it continuously for 30 days. Step 3: Result evaluation. After storage, take out the sample, restore it to room temperature, and observe whether the sample shows stratification, precipitation, clumping, gelation, or demulsification. If there are no abnormalities, it is qualified.

[0087] 6. Self-healing performance test The testing steps are as follows: Step 1: Sample preparation. Take a standard test sample and use a special scribing tool to scratch through the coating to the substrate. The scratch length is 50mm and the width is 0.3±0.05mm. Step 2: Self-healing curing. Place the scratched sample in a constant temperature and humidity chamber at 25°C and 95% relative humidity for 48 hours. Step 3: Salt spray resistance verification. The cured sample was subjected to a 1000-hour neutral salt spray test according to GB / T 1771-2007. After the test, the width of the scratch on one side was measured. The smaller the width of the scratch, the better the self-healing performance.

[0088] Performance Test Results Summary Table

[0089] Test Result Analysis The comprehensive protective performance of all embodiments of the present invention is far superior to that of conventional waterborne epoxy coatings in Comparative Example 1. The salt spray resistance time of the scratch-free sample is increased by more than 100%, the wear resistance weight loss is reduced by more than 60%, and it also has excellent self-healing properties. It completely solves the core pain points of existing outdoor coatings in the background technology, such as poor weather resistance, easy failure, lack of self-healing ability, and high maintenance costs, and achieves unexpected technical effects.

[0090] In Comparative Example 2, the salt spray resistance and self-healing properties of the coating were completely lost after the core sodium chloride microsphere component of the present invention was missing. This proves that the sodium chloride microspheres coated with corrosion inhibitor are the core and essential technical feature of the present invention to achieve intelligent self-healing and long-term corrosion protection, and cannot be replaced.

[0091] Comparative Example 3 used non-microencapsulated molybdenum disulfide powder, and the wear resistance of the coating decreased significantly. This proves that the design of microencapsulated solid lubricant is a necessary technical feature to achieve long-term wear resistance and wear self-repair of the coating, and can avoid premature failure of solid lubricant during preparation and storage.

[0092] Comparative Example 4 used sodium chloride microspheres without a hydrophobic coating of zinc stearate. The coating showed severe chloride ion accelerated corrosion, a significant decrease in salt spray resistance, and abnormal storage stability. This proves that the hydrophobic coating design of the present invention completely solves the corrosion risk caused by the release of chloride ions from the dissolution of sodium chloride. The principle of the solution is self-consistent and does not violate the common sense of corrosion prevention.

[0093] Comparative Example 5 used high-speed stirring to disperse the core functional components, and the overall performance of the coating completely failed. This proves that the process limitation of low-speed stirring in the preparation method is a necessary technical feature to ensure the integrity of the sodium chloride microsphere coating layer and the microcapsule wall structure, and is a key process control point to achieve the core function.

[0094] Comparative Example 6 deviated from the pH range defined by this invention, and the storage stability and protective performance of the coating decreased significantly. This proves that controlling the pH value of the system within the range of 8.0-9.0 is a necessary technical feature to ensure the storage stability of the water-based system and the controllability of the curing reaction.

[0095] All embodiments of this invention exhibit excellent storage stability, with no issues of layering, gelation, or demulsification. They are suitable for industrial mass production and outdoor on-site construction, demonstrating strong industrial feasibility. Furthermore, three parallel replicates of the core embodiment 2 were performed, and the relative deviations of all performance test results were ≤5%, proving that this technical solution possesses excellent repeatability and stability. Those skilled in the art can repeat this invention without creative effort by following the contents of this specification.

[0096] The test results of the above embodiments and comparative examples fully verify the effectiveness, stability, and inventiveness of the technical solution of the present invention. The anti-corrosion and wear-resistant coatings prepared in all embodiments of the present invention exhibit significantly better salt spray resistance, wear resistance, adhesion, and flexibility than the existing conventional water-based epoxy heavy-duty anti-corrosion coating shown in Comparative Example 1. They also possess excellent self-healing capabilities, completely solving the core pain points of existing outdoor protective coatings, such as insufficient anti-corrosion and wear resistance, lack of long-term self-healing function, and short service life. Comparative Examples 2-6, using a single variable comparison, clearly demonstrate that the sodium chloride microspheres with surface-coated corrosion inhibitors, the microencapsulated solid lubricant, and the accompanying hydrophobic coating structure, low-speed dispersion process, and precise pH control—all essential technical features for achieving the expected technical effects of the present invention—are crucial. The absence or deviation from any core design will lead to a significant decrease in the overall performance of the coating. Furthermore, the test results verify that the present invention, through the controllable triggering design of the hydrophobic coating and the hedging mechanism of synchronous release of the corrosion inhibitor, completely avoids the corrosion risk of chloride ions, demonstrating a self-consistent principle. The coating of this invention uses water as the dispersion medium, has extremely low VOC content, can be cured at room temperature, and is easy to apply. All embodiments exhibit excellent storage stability and batch repeatability, enabling stable industrial mass production and outdoor on-site construction, thus fully achieving all the inventive objectives set forth in this invention.

[0097] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An outdoor high-performance anti-corrosion and wear-resistant coating, comprising a film-forming resin base, functional fillers, additives, and a curing agent, characterized in that, It also includes core pore-forming and repair components, with each raw material comprising, by weight: Film-forming resin base: 30-50 parts of waterborne epoxy resin emulsion, 10-20 parts of waterborne polyurethane dispersion; Functional fillers: 0.5-2 parts graphene oxide, 5-10 parts flaky mica powder, and 3-8 parts modified nano silica; Core pore-forming and repair components: 5-15 parts of sodium chloride microspheres coated with corrosion inhibitor, and 3-10 parts of microencapsulated solid lubricant; the sodium chloride microspheres coated with corrosion inhibitor have sodium chloride as the core, the core surface is coated with a zinc stearate hydrophobic isolation layer, and the surface of the zinc stearate hydrophobic isolation layer is loaded with corrosion inhibitor. Additives: 0.5-1.5 parts wetting and dispersing agent, 0.1-0.5 parts defoamer, 0.2-0.8 parts leveling agent, pH adjuster, wherein the amount of pH adjuster is the amount used to adjust the pH value of the system to 8.0-9.0; Curing agent: water-based epoxy curing agent, wherein the amount of water-based epoxy curing agent added is matched with the epoxy equivalent of the water-based epoxy resin emulsion, and the corresponding weight parts are 8-15 parts.

2. The outdoor high-performance anti-corrosion and wear-resistant coating according to claim 1, characterized in that, The corrosion inhibitor is sodium molybdate or benzotriazole.

3. The outdoor high-performance anti-corrosion and wear-resistant coating according to claim 1, characterized in that, The microencapsulated solid lubricant is prepared by in-situ polymerization or complex coagulation, using polyurea or gelatin-gum arabic as the wall material and molybdenum disulfide or graphite powder as the core material.

4. The outdoor high-performance anti-corrosion and wear-resistant coating according to claim 1, characterized in that, The modified nano-silica is nano-silica with a surface hydrophobic modification by a silane coupling agent, and the particle size is 20-100 nm.

5. The outdoor high-performance anti-corrosion and wear-resistant coating according to claim 1, characterized in that, The solid content of the aqueous epoxy resin emulsion is 48%-52%, and the epoxy equivalent is 190-210 g / eq; the solid content of the aqueous polyurethane dispersion is 33%-37%.

6. The outdoor high-performance anti-corrosion and wear-resistant coating according to claim 1, characterized in that, The sodium chloride microspheres coated with corrosion inhibitors have a particle size of 30-100 μm, and the microencapsulated solid lubricant has a particle size of 10-50 μm.

7. A method for preparing an outdoor high-performance anti-corrosion and wear-resistant coating according to any one of claims 1-6, characterized in that, Specifically, the following steps are included: S1 Premix: Under stirring, add wetting and dispersing agent, defoamer, and 1 / 2 of the formula amount of leveling agent to deionized water in sequence, stir evenly to obtain a premixed solution; S2 Filler dispersion: Slowly add graphene oxide, flake mica powder, and modified nano silica to the premixed solution obtained in S1, and disperse at high speed until the system fineness is ≤30μm to obtain the filler dispersion; S3 Resin Mixing: Reduce the stirring speed to below 300 rpm, add waterborne epoxy resin emulsion and waterborne polyurethane dispersion to the filler dispersion obtained in S2 in sequence, stir evenly to obtain resin base liquid; S4 Functional Component Addition: Add sodium chloride microspheres coated with corrosion inhibitor and microencapsulated solid lubricant to the resin base liquid obtained in S3, and stir at a speed of 100-300 rpm until uniformly dispersed to avoid high-speed shearing damaging the coating / capsule structure of the components. S5 Paint Mixing: Adjust the pH of the system to 8.0-9.0 with a pH adjuster, add the remaining leveling agent, stir evenly, and obtain the paint base material; S6 Curing and Application: Add water-based epoxy curing agent to the coating base obtained from S5, stir evenly, and cure for 20-30 minutes. Then apply it to the pretreated substrate and cure it at room temperature or below 80°C to form a film.

8. The preparation method according to claim 7, characterized in that, In step S6, the construction method is spraying or brushing; the substrate is a metal substrate that has been sandblasted to Sa2.5 grade, and the dry film thickness of the coating after curing is controlled to be 100-200μm.

9. The application of the outdoor high-performance anti-corrosion and wear-resistant coating according to any one of claims 1-6 in the long-term protection of the metal surfaces of outdoor scientific and educational equipment, amusement facilities, and sports equipment.

10. The application of the outdoor high-performance anti-corrosion and wear-resistant coating according to any one of claims 1-6 in the long-term protection of metal surfaces of ships, high-speed railways, and marine engineering equipment.

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