A water-based organic-inorganic hybrid coating and its preparation method

Abstract

This invention discloses a water-based organic-inorganic hybrid coating and its preparation method. The coating comprises, by mass percentage: 35-40% water-based inorganic resin, 5-10% zinc phosphate, 3-5% nano-sized silica, 25-35% zinc base, 3-5% water-based dispersant, 10-20% functional filler, and the balance deionized water. The preparation method includes: high-speed dispersion of the water-based inorganic resin and other components to form component A; then adding the zinc base and functional filler to component A and stirring until homogeneous. This invention, through process optimization, improves the coating's compatibility, adhesion, and corrosion resistance. It contains no harmful volatile substances, is simple to prepare, suitable for the protection of various substrates, and combines environmental friendliness with practicality.

Description

Technical Field

[0001] This invention relates to the field of coating technology, specifically to a water-based organic-inorganic hybrid coating and its preparation method. Background Technology

[0002] In existing technologies, organic coatings, due to their molecular structure, possess good flexibility and workability, but they have significant shortcomings in acid and alkali corrosion resistance, high temperature resistance, and abrasion resistance. Long-term exposure to outdoor or harsh environments easily leads to coating aging, peeling, and cracking, making it difficult to meet the long-term protection requirements of metals, building materials, and other substrates. Inorganic coatings, while exhibiting excellent corrosion resistance and high temperature resistance, suffer from poor flexibility, weak adhesion to substrates, and poor film-forming properties. Furthermore, they are prone to sagging and pinholes during application, limiting their application range. Meanwhile, traditional solvent-based coatings use organic solvents as diluents, releasing large amounts of VOCs (volatile organic compounds) during use. This not only pollutes the atmosphere but also poses serious health risks to operators, contradicting current green, environmentally friendly, and low-carbon development policies. While existing water-based organic-inorganic hybrid coatings attempt to combine the advantages of both organic and inorganic coatings and possess environmentally friendly characteristics, they generally suffer from poor component compatibility. Layering and aggregation easily occur between water-based inorganic resins, organic components, and functional fillers, leading to poor storage stability and insufficient coating density after application. This, in turn, affects the coating's adhesion, corrosion resistance, and abrasion resistance. Therefore, developing an environmentally friendly, high-performance, storage-stable, and scientifically efficient water-based organic-inorganic hybrid coating and its corresponding preparation method has become a pressing technical challenge in the coatings industry. Summary of the Invention

[0003] The purpose of this invention is to provide a water-based organic-inorganic hybrid coating with good compatibility, strong adhesion, and excellent corrosion resistance, and to provide a simple, efficient, and stable preparation method to solve the performance defects and pain points in the preparation process of existing water-based coatings.

[0004] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A water-based organic-inorganic hybrid coating, by mass percentage, comprises at least the following components: 35-40% water-based inorganic resin, 5-10% zinc phosphate, 3-5% nano-sized silica, 25-35% zinc base, 3-5% water-based dispersant, 10-20% functional filler, and the remainder being deionized water, wherein the sum of the mass percentages of each component is 100%.

[0005] In a preferred embodiment, the water-based dispersant is a fluorinated water-based dispersant.

[0006] In a preferred embodiment, the nanoscale silica is used to improve the continuity and density of the inorganic framework of the coating, and it is bonded to the zinc phosphate network via hydrogen bonds.

[0007] A method for preparing a water-based organic-inorganic hybrid coating includes at least the following steps: (1) Take 35%-40% water-based inorganic resin, 5%-10% zinc phosphate, 3%-5% water-based dispersant and 3%-5% nano-sized silica according to the above proportions, and carry out high-speed dispersion treatment. The dispersion time is ≥30min, and the fineness of the dispersed material is controlled to be ≤10μm. Prepare component A for later use.

[0008] (2) When using, add zinc base material and functional filler to component A prepared in step (1), and mix while stirring until the material is evenly mixed to obtain the water-based organic-inorganic hybrid coating.

[0009] In a preferred embodiment, the high-speed dispersion rotation speed in step (1) is set such that the components are fully mixed and the fineness of the dispersed material is ≤10μm.

[0010] In a preferred embodiment, uniform stirring is used in step (2) to ensure that the zinc base material, functional filler and component A are fully integrated and there is no clumping.

[0011] In a preferred embodiment, during the high-speed dispersion in step (1), the dispersion temperature is controlled at 25-30℃ for the first 10-15 minutes and then raised to 35-40℃ for the next 15-20 minutes. The dispersion speed is kept constant throughout the process to ensure that the fineness of the dispersed material is ≤8μm and that the hydrogen bonding efficiency between the water-based inorganic resin and zinc phosphate is increased by more than 30%.

[0012] In a preferred embodiment, in step (2), after adding zinc base material and functional filler to component A, the mixture is first stirred at a constant speed for 5-8 minutes at 20-25°C, then the temperature of the stirring system is rapidly increased to 45-50°C within 1-2 minutes and stirred at a constant speed for 3-5 minutes, and finally the temperature is rapidly reduced to 25-30°C within 1-2 minutes and the mixture is stirred until the material is evenly mixed.

[0013] In a preferred embodiment, in step (1), after the high-speed dispersion is completed and before the A component is prepared for use, the dispersed material is subjected to vacuum degassing treatment. The vacuum degree is controlled at -0.08 to -0.09 MPa, the degassing time is 8-10 min, and the material temperature is maintained at 35-40℃ and the rotation speed is maintained at 200-300 r / min during the degassing process.

[0014] In a preferred embodiment, during the initial 5-6 minutes of degassing, the vacuum level is gradually increased from -0.05 MPa to -0.09 MPa. During the later 2-4 minutes of degassing, the vacuum level is kept stable at -0.08 to -0.09 MPa. Throughout the process, the material temperature is maintained at 35-40°C and the rotation speed is maintained at 200-300 r / min. Inert protective gas is simultaneously introduced during the degassing process at a rate of 5-8 mL / min.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. The coating of this invention adopts an organic-inorganic hybrid synergistic system. By rationally proportioning components such as water-based inorganic resin, zinc phosphate, and nano-sized silica, the organic and inorganic phases are uniformly fused. This retains the good flexibility, workability, and film-forming properties of organic coatings while also possessing the excellent corrosion resistance, high-temperature resistance, and wear resistance of inorganic coatings. This effectively solves the technical pain points of poor corrosion resistance in existing organic coatings and insufficient flexibility in inorganic coatings. At the same time, the nano-sized silica and zinc phosphate form a stable hydrogen bond network, further improving the continuity and density of the inorganic skeleton of the coating, enhancing the density and impermeability of the coating, effectively blocking the erosion of the substrate by moisture and corrosive media, and significantly extending the service life of the substrate.

[0016] 2. This invention adopts a fully water-based system, using deionized water as the dilution medium, without adding any organic solvents, with no VOC emissions, and will not cause pollution to the environment or harm the health of operators. It fully complies with the national green chemical and low-carbon environmental protection development policies, meets the current environmental upgrade needs of the coating industry, has a wider range of applications, and can be used for substrate protection in various indoor and outdoor scenarios.

[0017] 3. The preparation method of the present invention is scientific and reasonable. Through the optimization of multiple process parameters, it effectively solves the problems of uneven component dispersion, agglomeration, residual bubbles, and insufficient coating adhesion in the existing preparation process, ensuring that the components of the coating are fully integrated, have good storage stability, and are not prone to layering or clumping. At the same time, the preparation process is simple and easy to understand, requires no complicated production equipment, is convenient to operate, has high production efficiency, and is cost-controllable. It can realize large-scale industrial production and is easy to promote and apply.

[0018] 4. The components of the coating of this invention have good compatibility. After construction, the coating is tightly bonded to the substrate, with strong adhesion, and is not prone to problems such as peeling, cracking, or sagging. Moreover, the coating surface is smooth and has excellent appearance quality. In addition, the coating has good weather resistance, wear resistance, and acid and alkali corrosion resistance. It can be widely used for the protection of various substrates such as metals, building materials, furniture, and ships. It has diverse application scenarios and is extremely practical. Detailed Implementation

[0019] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention. Example

[0020] A water-based organic-inorganic hybrid coating, by mass percentage, comprises at least the following components: 35-40% water-based inorganic resin, 5-10% zinc phosphate, 3-5% nano-sized silica, 25-35% zinc base, 3-5% water-based dispersant, 10-20% functional filler, and the remainder being deionized water, wherein the sum of the mass percentages of each component is 100%.

[0021] When preparing this coating, each component is accurately weighed according to the above-mentioned mass percentages. Among them, the water-based inorganic resin serves as the base component to provide the film-forming basis, zinc phosphate plays a role in corrosion protection and reinforcement, nano-sized silica is used to construct a dense inorganic skeleton, zinc base material improves the wear resistance and protective performance of the coating, water-based dispersant ensures uniform dispersion of each component, functional filler optimizes the overall performance of the coating, and deionized water is used as the dispersion medium to avoid the use of harmful solvents. After mixing each component in proportion, a uniform and stable coating system is formed through subsequent dispersion, stirring and other processes. This effectively balances the flexibility and corrosion resistance of the coating, solves the problem of single organic or inorganic coatings having limited performance, and allows the coating to have both good film-forming properties and excellent weather resistance and protection, meeting various protective needs in practical applications.

[0022] Furthermore, the water-based dispersant is a fluorine-containing water-based dispersant.

[0023] When selecting a fluorinated water-based dispersant, it is mixed with other components according to the corresponding mass percentage. Utilizing the surface-active properties of the fluorinated groups, the interfacial tension between components is reduced, promoting the full integration of components such as water-based inorganic resin, zinc phosphate, and nano-sized silica. This effectively avoids stratification and agglomeration of the components, while improving the stability of the dispersion system. This ensures that the coating will not precipitate or clump during storage and use, thereby guaranteeing the uniformity and consistency of the coating and improving the overall performance of the coating.

[0024] Furthermore, the nanoscale silica is used to improve the continuity and density of the inorganic skeleton of the coating, and it is bonded to the zinc phosphate network through hydrogen bonds.

[0025] In the coating system, nano-sized silica is uniformly dispersed among the components. The hydroxyl groups on its surface form stable hydrogen bonds with the active groups in the zinc phosphate molecules, constructing a continuous inorganic network structure. This hydrogen bonding method can fill the tiny gaps inside the coating, enhance the integrity and density of the inorganic skeleton, reduce the penetration of external moisture and corrosive media, and at the same time improve the mechanical strength of the coating, avoid problems such as cracking and peeling of the coating, and extend the service life of the coating. Example

[0026] A method for preparing a water-based organic-inorganic hybrid coating includes at least the following steps: (1) Take 35%-40% water-based inorganic resin, 5%-10% zinc phosphate, 3%-5% water-based dispersant and 3%-5% nano-sized silica according to the above proportions, and carry out high-speed dispersion treatment. The dispersion time is ≥30min, and the fineness of the dispersed material is controlled to be ≤10μm. Prepare component A for later use.

[0027] (2) When using, add zinc base material and functional filler to component A prepared in step (1), and mix while stirring until the material is evenly mixed to obtain the water-based organic-inorganic hybrid coating.

[0028] When performing this preparation method, each component is first accurately weighed and put into a dispersion device. High-speed stirring is used to ensure that the components are fully contacted and mixed, and the dispersion time is controlled to be no less than 30 minutes to ensure that the material particles are refined to below 10μm and form a uniform component A. This process can break the agglomeration of each component and lay the foundation for subsequent fusion with zinc base material and functional filler. Then, zinc base material and functional filler are slowly added to component A while continuous stirring is maintained to ensure that zinc base material and functional filler are uniformly dispersed in component A, and finally a stable coating is formed. The whole process does not require complicated equipment, is easy to operate, and can effectively ensure that the components of the coating are mixed uniformly and avoid the problem of uneven local performance.

[0029] Furthermore, the high-speed dispersion rotation speed in step (1) should be such that the components are fully mixed and the fineness of the dispersed material is ≤10μm.

[0030] When determining the high-speed dispersion speed, it is necessary to adjust it in conjunction with the power of the dispersion equipment and the viscosity of the material. This ensures that the speed can drive the components to move fully and break up agglomerates, but also prevents the molecular chains of water-based inorganic resin or the nano-sized silica from breaking due to excessive speed. By reasonably controlling the speed, the water-based inorganic resin, zinc phosphate, water-based dispersant, and nano-sized silica can be fully integrated, ensuring that the fineness of the dispersed material meets the requirements. This provides a guarantee for the subsequent molding and performance stability of the coating, while avoiding material waste or performance defects caused by improper speed.

[0031] Furthermore, in step (2), uniform stirring is used to ensure that the zinc base material, functional filler and component A are fully integrated and there is no clumping.

[0032] During the stirring process in step (2), a constant stirring speed is maintained to avoid stirring too fast, which would cause material splashing and uneven mixing, or stirring too slowly, which would prevent the zinc base material and functional filler from being fully dispersed in component A. By stirring at a uniform speed, the zinc base material and functional filler are fully contacted with the water-based inorganic resin, zinc phosphate and other components in component A to form a uniform mixing system, which effectively prevents problems such as local clumping and layering, ensures the overall performance of the coating is consistent, and improves the smoothness and adhesion of the coating.

[0033] Furthermore, in the high-speed dispersion of step (1), the dispersion temperature is controlled at 25-30℃ for the first 10-15 minutes, and then raised to 35-40℃ for the next 15-20 minutes. The dispersion speed is kept constant throughout the process to ensure that the fineness of the dispersed material is ≤8μm, and the hydrogen bonding efficiency between the water-based inorganic resin and zinc phosphate is increased by more than 30%.

[0034] In the initial stage of high-speed dispersion, controlling the temperature at 25-30℃ can prevent the water-based inorganic resin from curing prematurely due to excessive temperature, ensuring that all components can be fully dissolved and dispersed. In the later stage, raising the temperature to 35-40℃ can promote the formation of hydrogen bonds between the water-based inorganic resin and zinc phosphate, improve the hydrogen bond bonding efficiency, and accelerate the dispersion of nano-sized silica, so that the fineness of the dispersed material is controlled below 8μm, further improving the compatibility of each component and the density of the coating, providing support for the stable performance of the subsequent coating.

[0035] Further, in step (2), after adding zinc base material and functional filler to component A, stir at a constant speed for 5-8 minutes at 20-25℃, then rapidly raise the temperature of the stirring system to 45-50℃ within 1-2 minutes and maintain constant stirring for 3-5 minutes, and finally rapidly cool down to 25-30℃ within 1-2 minutes and continue stirring until the material is evenly mixed.

[0036] First, stir at 20-25℃ for 5-8 minutes to initially disperse the zinc base and functional fillers on the surface of component A, avoiding agglomeration caused by excessively rapid reaction of local components due to direct heating. Then, rapidly heat to 45-50℃ and keep stirring for 3-5 minutes to promote the fusion of zinc base and water-based inorganic resin in component A, enhancing their bonding strength. Finally, rapidly cool to 25-30℃ and continue stirring to inhibit excessive movement of resin molecules, preventing cracking after coating formation, while ensuring thorough mixing of all components, improving the uniformity and stability of the coating.

[0037] Furthermore, in step (1), after the high-speed dispersion is completed and before the A component is prepared for use, the dispersed material is subjected to vacuum degassing treatment. The vacuum degree is controlled at -0.08 to -0.09 MPa, the degassing time is 8-10 min, and the material temperature is maintained at 35-40℃ and the rotation speed is maintained at 200-300 r / min during the degassing process.

[0038] During vacuum degassing, the dispersed material is placed in a vacuum device, and the vacuum level is adjusted to -0.08 to -0.09 MPa. The material temperature is maintained at 35-40℃ and the rotation speed is 200-300 r / min. Degassing is continued for 8-10 minutes. During this process, tiny bubbles in the material will precipitate and be discharged under vacuum, preventing bubbles from remaining in component A. This prevents defects such as pinholes and bubbles from appearing after the coating is formed. At the same time, the dispersion of the material is maintained, ensuring the uniformity of component A, which lays the foundation for subsequent mixing with zinc base material and functional fillers.

[0039] Furthermore, during the initial 5-6 minutes of degassing, the vacuum level is gradually increased from -0.05 MPa to -0.09 MPa. During the later 2-4 minutes of degassing, the vacuum level is kept stable at -0.08 to -0.09 MPa. Throughout the process, the material temperature is maintained at 35-40℃ and the rotation speed is 200-300 r / min. Inert protective gas is simultaneously introduced during the degassing process at a rate of 5-8 mL / min.

[0040] In the initial stage of degassing, a gradient pressure increase is adopted, gradually increasing from -0.05MPa to -0.09MPa. This avoids material splashing or damage to the component structure caused by excessively high local vacuum due to a sudden increase in vacuum. In the later stage of degassing, a stable vacuum is maintained to ensure that the tiny bubbles in the material are fully discharged. The introduction of inert protective gas can effectively isolate air and prevent the water-based inorganic resin, zinc phosphate and other components from undergoing oxidation reactions in a vacuum environment, thus avoiding a decline in coating performance. At the same time, it protects the dispersion state of the material and further improves the stability of component A.

[0041] In this embodiment, during the rapid temperature rise and fall, the pressure of the stirring system is simultaneously controlled at 0.12-0.15 MPa. During the heating phase, the pressure increases synchronously with the temperature increase, rising by 0.01 MPa for every 5°C increase. During the cooling phase, the pressure decreases synchronously with the temperature decrease, decreasing by 0.01 MPa for every 5°C decrease. Simultaneously, at each stage of rapid heating and cooling, 0.3-0.5% of the mass of component A is added, and uniform stirring is maintained without interruption after addition. Synchronously controlling the system pressure during rapid temperature rise and fall, ensuring that the pressure matches the temperature, effectively suppresses the volume shrinkage or expansion of the material due to sudden temperature changes, preventing problems such as coating cracking and peeling. Adding an appropriate amount of deionized water at each stage of heating and cooling adjusts the viscosity of the material, promotes further integration of the components, and prevents the viscosity from becoming too high or too low due to temperature changes, ensuring smooth stirring. It also improves the bonding tightness between the zinc base material, functional fillers, and component A, further optimizing the adhesion and density of the coating.

[0042] The test indicators of the coatings obtained in the above embodiments are shown in Table 1 below: Table 1

[0043] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Unless otherwise specified, an element defined by the phrase "comprising..." or "including..." does not exclude the presence of additional elements in the process, method, article, or terminal device that includes said element. Additionally, in this document, "greater than," "less than," "exceeding," etc., are understood to exclude the stated number; "above," "below," "within," etc., are understood to include the stated number.

[0044] The above description of the embodiments is provided to facilitate understanding and use of the present invention by those skilled in the art. It is obvious to those skilled in the art that various modifications can be easily made to the embodiments, and the general principles described herein can be applied to other embodiments without creative effort. Therefore, the present invention is not limited to the above embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the protection scope of the present invention.

Claims

1. A water-based organic-inorganic hybrid coating, characterized in that, The coating comprises, by mass percentage, at least the following components: 35-40% waterborne inorganic resin, 5-10% zinc phosphate, 3-5% nano-sized silica, 25-35% zinc base, 3-5% water-based dispersant, 10-20% functional filler, and the remainder being deionized water, with the sum of the mass percentages of each component being 100%.

2. The water-based organic-inorganic hybrid coating according to claim 1, characterized in that, The water-based dispersant is a fluorine-containing water-based dispersant.

3. The water-based organic-inorganic hybrid coating according to claim 1, characterized in that, The nanoscale silica is used to improve the continuity and density of the inorganic skeleton of the coating, and it is bonded to the zinc phosphate network through hydrogen bonds.

4. A method for preparing a water-based organic-inorganic hybrid coating as described in any one of claims 1-3, characterized in that, At least the following steps are included: (1) Take 35%-40% water-based inorganic resin, 5%-10% zinc phosphate, 3%-5% water-based dispersant and 3%-5% nano-sized silica according to the above proportions, and carry out high-speed dispersion treatment. The dispersion time is ≥30min, and the fineness of the dispersed material is controlled to be ≤10μm. Prepare component A for later use. (2) When using, add zinc base material and functional filler to component A prepared in step (1), and mix while stirring until the material is evenly mixed to obtain the water-based organic-inorganic hybrid coating.

5. The method for preparing a water-based organic-inorganic hybrid coating according to claim 4, characterized in that, In step (1), the high-speed dispersion speed should be such that the components are fully mixed and the fineness of the dispersed material is ≤10μm.

6. The method for preparing a water-based organic-inorganic hybrid coating according to claim 4, characterized in that, In step (2), uniform stirring is used to ensure that the zinc base material, functional filler and component A are fully mixed and there is no clumping.

7. The method for preparing a water-based organic-inorganic hybrid coating according to claim 4, characterized in that, In the high-speed dispersion of step (1), the dispersion temperature is controlled at 25-30℃ for the first 10-15 minutes, and then raised to 35-40℃ for the next 15-20 minutes. The dispersion speed is kept constant throughout the process to ensure that the fineness of the dispersed material is ≤8μm and that the hydrogen bonding efficiency between the water-based inorganic resin and zinc phosphate is increased by more than 30%.

8. The method for preparing a water-based organic-inorganic hybrid coating according to claim 4, characterized in that, In step (2), after adding zinc base material and functional filler to component A, stir at a constant speed for 5-8 minutes at 20-25℃, then rapidly raise the temperature of the stirring system to 45-50℃ within 1-2 minutes and maintain constant stirring for 3-5 minutes, and finally rapidly cool down to 25-30℃ within 1-2 minutes and continue stirring until the material is evenly mixed.

9. The method for preparing a water-based organic-inorganic hybrid coating according to claim 4, characterized in that, In step (1), after the high-speed dispersion is completed and before the A component is prepared for use, the dispersed material is subjected to vacuum degassing treatment. The vacuum degree is controlled at -0.08 to -0.09 MPa, the degassing time is 8-10 min, the material temperature is maintained at 35-40℃ and the rotation speed is maintained at 200-300 r / min.

10. The method for preparing a water-based organic-inorganic hybrid coating according to claim 9, characterized in that, During the initial 5-6 minutes of degassing, the vacuum level is gradually increased from -0.05 MPa to -0.09 MPa. During the later 2-4 minutes of degassing, the vacuum level is kept stable between -0.08 and -0.09 MPa. Throughout the process, the material temperature is maintained at 35-40℃ and the rotation speed is 200-300 r / min. Inert protective gas is simultaneously introduced during the degassing process at a rate of 5-8 mL / min.

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