Corrosion inhibitor impregnated into elastomer rubber

Abstract

In one embodiment, the disclosure relates to a composition comprising an elastomer material and at least one corrosion inhibitor, preferably the at least one corrosion inhibitor being a corrosion inhibitor blend. The disclosure also relates to an elastomer material, such as a gasket, comprising an elastomer material and a corrosion inhibitor blend having at least one corrosion inhibitor. Preferably the elastomer material prevents corrosion of a metal surface it contacts. The disclosure also relates to a method for manufacturing an elastomer material, as well as a method for preventing corrosion, including contacting the elastomer material with a metal surface or placing it between two or more metal surfaces or joints.

Description

Technical Field

[0001] The disclosure herein relates to an elastomeric material comprising an elastomeric substance and a corrosion inhibitor blend. The corrosion inhibitor blend consists of one or more corrosion inhibitors such that the elastomeric material exhibits the properties of the elastomeric substance and the corrosion inhibitor blend. The disclosure also relates to gaskets and other elastomeric materials for use as an extrusion compression seal formed from an elastomeric material comprising an elastomeric substance and a corrosion inhibitor blend, such that exemplary gaskets are corrosion-resistant gaskets, dielectric galvanic insulation barrier materials, and to the edges of exemplary drain outlets. The disclosure further relates to a method of manufacturing an elastomeric material comprising a blend of an elastomeric substance and a corrosion inhibitor, and to a method of preventing corrosion by disposing a corrosion-resistant elastomeric material on a metal surface or between two or more metal surfaces.

Background Art

[0002] Corrosion is a process involving the deterioration of metals. This is typically the result of an electrochemical reaction that can occur when an acidic substance or a highly saline solution comes into contact with a metal in the presence of oxygen, causing the metal to begin to corrode. Moisture in the air can also react with oxygen and electrons on the metal surface, causing corrosion. Over time, this corrosion can lead to other problems such as weakened structures, damage to mechanical parts, poor appearance, the generation of friction that impedes the movement of metal components relative to each other, and poor electrical conduction and reduced magnetic attraction.

[0003] Corrosion can occur at any rate, depending in part on the environment in which the metal is placed. For example, atmospheric corrosion can be exacerbated under conditions of increased humidity, rising humidity, and / or exposure to water. In addition to the corrosion rate due to exposure to water, there is salt in, for example, seawater or salt spray. Exposure of metals to external environmental factors including, but not limited to, moisture, wind, water, acid rain, corrosive chemicals, and certain biological substances in the presence of oxygen can cause the oxidation of the metal and ultimately corrosion.

[0004] In some environments, corrosion can be minimized by providing climate-controlled facilities. However, metals are used in many applications, many of which cannot be carried out in climate-controlled environments. In such cases, corrosion may potentially be treatable or remedial, but the results may be unsatisfactory or not easily carried out. Therefore, other measures to minimize corrosion are taken, such as using products that cover the metal to protect it. Examples of these coverings may include painting, galvanizing, or coating (sacrificial or protective coating) the metal surface. Alternatively, manipulating the environment, such as by diverting water flow, may be useful.

[0005] Metals can also corrode where two metallic components meet. Metal corrosion can lead to changes in its shape, structure, and function, which can affect how two or more metallic surfaces interact and the function of the metal itself. Such changes can create areas of defects or leaks, further hindering efforts to replace these corroded metal parts.

[0006] Gaskets are commonly used to fill the space between two or more mating surfaces to prevent leaks or to provide a better fit. Gaskets are typically made of a deformable material that can form and maintain a seal in a mechanical assembly. These seals are often found between mating surfaces or between mechanical parts that have imperfect mating surfaces.

[0007] Gaskets are typically made from materials that have at least some degree of ability to deform while densely filling the space they occupy. Depending on the application, gaskets may also need to withstand high compressive loads. Gaskets include, but are not limited to, sheet gaskets, solid material gaskets, flange gaskets, and ring-type joint gaskets, and come in a variety of different designs and shapes.

[0008] When gaskets are used, it is crucial to select the correct gasket material to suit the application needs, considering the potential cost and safety impact of defective or leaking metal parts. Gaskets that can insulate any potential between metals and reduce the electrolyte-induced electron flow effect between them also help reduce corrosion of the metals interposed by the gasket, thereby preventing or reducing metal corrosion. Such gaskets must also maintain the rheology of the compressible polymer and the strength of the elastomer, protect against metal-to-metal contact, and provide a durable gap and a reliable compression seal against continuous pressure.

[0009] Another example of corrosion formation is a boat's drain. These openings in the side walls of a ship or vessel allow water to drain instead of accumulating within the ship's or vessel's sills or gun walls. Similar drains can be found in the curbs and walls of buildings. If a ship or building has metal components in such a drainage path, this water flow, whether from the drain itself or other building components, can cause the rust streaks commonly seen on the sides of ships. For example, the ability to minimize corrosion in the area surrounding a drain would be extremely useful. [Overview of the project] [Problems that the invention aims to solve]

[0010] Current attempts to prevent corrosion are unable to adequately prevent or control the level of corrosion. Whether in the form of liquids, paints, sprays, galvanizing sprays, rubber seals, oiled rubber seals, and other related items, currently available products and methods do not provide protection against continuous corrosion. [Means for solving the problem]

[0011] In the field of metal components, it is necessary to reduce corrosion when such metal components are exposed to corrosive conditions such as oxygen in high-humidity or high-salt environments. Corrosion inhibitors that can effectively latch onto the metal surface without changing position are of great benefit in protecting metals from corrosion and protecting them from corrosion in environments where they are continuously exposed to such corrosion-inducing elements.

[0012] In one embodiment, the present invention relates to an elastomer material comprising an elastomer substance and a corrosion inhibitor blend having one or more corrosion inhibitors. The corrosion inhibitor blend can polarly bond with a metal to prevent corrosion of the metal in contact with the elastomer material. The components of the elastomer material, including at least the corrosion inhibitor blend, are also uniformly distributed throughout the elastomer material. One or more corrosion inhibitors are selected from the group consisting of high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricants, bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salts with bentonite, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvents, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixtures, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate, which can polarize with metals and thereby prevent metal corrosion. The elastomer material includes at least one of the following: natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam. The elastomer material may further include one or more of the following: reinforcing fillers, spreading fillers, process oils, curing agents, and other specially formulated corrosion inhibitor additives.

[0013] In one embodiment, the present invention relates to a method for producing an elastomer material comprising an elastomer substance and a corrosion inhibitor blend, comprising: mixing one or more corrosion inhibitors to form a corrosion inhibitor blend; compounding the elastomer substance to an uncured paste consistency; injecting the corrosion inhibitor blend together with the elastomer substance during compounding until a compound material is formed; and then curing the compound material to form an elastomer material. The mixing of the corrosion inhibitor blend and its injection with the elastomer substance may further comprise specific mixing and injection sequences. Compounding may further comprise the addition of additives. The method may further comprise calendering during compounding, thereby facilitating the smoothing and compression of all components of the material, preferably removing dry / non-wet zones and removing uncurable areas of the compound material into which the corrosion inhibitor blend has been injected. The method may also comprise heating, mixing, molding, extrusion, molding, curing, or vulcanization.

[0014] In one embodiment, the present invention relates to a method for preventing metal corrosion, the method comprising placing an elastomer material in contact with a metal, thereby the elastomer material comprising an elastomer substance and a corrosion inhibitor blend. The corrosion inhibitor blend comprises one or more corrosion inhibitors. The corrosion inhibitor blend can bleed out from the elastomer material and polarize with the metal. The elastomer material can prevent corrosion of the metal surface it contacts. The elastomer material may be a gasket or the edge of a drain. [Effects of the Invention]

[0015] In the field of metal components, it is necessary to reduce corrosion when such metal components are exposed to corrosive conditions such as oxygen in high-humidity or high-salt environments. Corrosion inhibitors that can effectively latch onto the metal surface without changing position are of great benefit in protecting metals from corrosion and protecting them from corrosion in environments where they are continuously exposed to such corrosion-inducing elements. [Brief explanation of the drawing]

[0016] The following detailed description of embodiments of the present invention will be better understood in conjunction with the accompanying drawings. However, it should be understood that the present invention is not limited to the exact configurations shown. The drawings are as follows:

[0017] [Figure 1] Figure 1 shows a cross-sectional view of a material containing ethylene propylene diene monomer (EPDM) without a corrosion inhibitor blend. [Figure 2] Figure 2 shows a cross-sectional view of a material containing ethylene propylene diene monomer (EPDM) in which a corrosion inhibitor blend is uniformly dispersed throughout the entire thickness of the EPDM. [Figure 3] Figure 3 shows a cross-sectional view of a material containing ethylene propylene diene monomer (EPDM) in which a corrosion inhibitor blend is uniformly dispersed throughout the entire thickness of the EPDM, under compression, and in full contact with a metal surface. [Figure 4] Figure 4 shows a perspective view of a material in the form of a drain rim, containing an elastomer material and a corrosion inhibitor blend. [Figure 5] Figure 5 shows a method for forming an ethylene propylene diene monomer (EPDM) compound injected with a corrosion inhibitor blend. [Figure 6A] Figure 6A shows the new flange assembly. [Figure 6B] Figure 6B shows a flange assembly having an EPDM-based gasket material containing a corrosion inhibitor blend. [Figure 6C] Figure 6C shows an assembled flange with gasket material immersed in 32% hydrochloric acid. [Figure 6D] Figure 6D shows a flange assembled with the gasket material immersed in a super saline solution. [Figure 6E] Figure 6E shows an assembled flange with gasket material after immersion in 32% hydrochloric acid for 24 hours, followed by immersion in high saline solution for 24 hours, and then drying for 24 hours. [Figure 6F] Figure 6F shows the inner surface of the flange that was in contact with the gasket during immersion.

[0018] Detailed description In the following description, for convenience, certain terms are used, but are not limited thereto. When a list of two or more items such as "A, B, or C" or "A, B, and C" follows the phrase "at least one", it means any individual one of A, B, or C, and any combination thereof. Terms such as "approximately", "about", "substantially", etc. are defined by the context and are construed as modifying terms as understood by those skilled in the art. The terms "corrosion" and "rust" are construed as equivalent in that a metal may corrode and rust may or may not form depending on the type of metal used. The term "inject or injected" may also refer to "mix or mixed". The term "dissimilar metals" may refer to two different metal types, two similar metal types having a combination of different metals, or any two metals having a sufficient difference such that the metals have different electrode potentials, where one metal acts as the anode and the other metal acts as the cathode. The terms "uniform distribution" and "spread evenly" may be used interchangeably.

[0019] One embodiment includes a composition consisting essentially of or consisting of a blend of an elastomeric material and a corrosion inhibitor. The corrosion inhibitor blend can include one or more corrosion inhibitors selected from the group consisting of a high-viscosity petroleum C20-50 hydrotreated neutral oil-based lubricating oil, bis(hydrotreated tallow alkyl)dimethyl quaternary ammonium salt with bentonite, hydrotreated heavy naphtha, dinonyl-naphthalene sulfonic acid calcium salt, calcium carbonate, hydrotreated light petroleum distillate, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonyl naphthalene sulfonic acid, calcium dinonyl naphthalene sulfonate / carboxylate, or zinc alkyl naphthalene sulfonate / carboxylate. In one embodiment, the corrosion inhibitor blend includes a high-viscosity petroleum C20-50 hydrotreated neutral oil-based lubricating oil, bis(hydrotreated tallow alkyl)dimethyl quaternary ammonium salt with bentonite, hydrotreated heavy naphtha (petroleum), dinonyl-naphthalene sulfonic acid calcium salt, calcium carbonate, hydrotreated light petroleum distillate, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene. The corrosion inhibitor blend may include a polar bonded oil carrier for the corrosion inhibitor.

[0020] The concentration range of the corrosion inhibitor in the corrosion inhibitor blend can be in a concentration range according to Table 1 below, or in a sub-range concentration range according to Table 1 below.

[0021]

Table 1

[0022] The corrosion inhibitor blend may have a concentration of about 1 to 30% by weight in the composition. In one embodiment, the corrosion inhibitor blend has concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or any interval between any concentration range. In one embodiment, the corrosion inhibitor blend has a concentration of 20-22% in the composition. According to one embodiment, the corrosion inhibitor blend has a concentration of 20% in the composition. According to one embodiment, the corrosion inhibitor blend has a concentration of 22% in the composition. According to one embodiment, the corrosion inhibitor blend includes a corrosion-preventive polarity-binding oil carrier.

[0023] Elastomer materials can include one or more of the following: natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam materials, closed-cell foam materials, fine-cell foams, and chemically cross-linked polyethylene foams. According to one embodiment, the elastomer material is elastic. Elasticity can be achieved in the elastomer material itself. Elasticity can also be achieved by various additives and chemicals to ensure that the elastic material has elastic properties and flexibility to the extent that it is deformable and can return to its previous shape. This ability to deform and return to its original shape can be said to have "memory".

[0024] In one embodiment, the composition further comprises additives. The additives may be at least one of reinforcing fillers, bulking agents, oils, stabilizers, tackifiers, resins, curing agents, and other specially formulated corrosion inhibitor additives. Depending on the specific elastomer material selected, additives and chemicals may be included.

[0025] In one embodiment, the corrosion inhibitor blend replaces the standard manufacturing oil in the composition. In one embodiment, the composition comprises the corrosion inhibitor blend and the standard manufacturing oil. In this example, the concentration of the corrosion inhibitor blend is lower than the concentration of the corrosion inhibitor blend in a composition that contains the corrosion inhibitor blend without the standard manufacturing oil. The combined concentration of the corrosion inhibitor blend and the standard manufacturing oil must not exceed a combined concentration that would impair the elastomeric properties of the composition.

[0026] In one embodiment, the corrosion inhibitor blend is uniformly distributed throughout the composition. All elements of the composition, including the corrosion inhibitor blend, elastomer material, and any additives, can be uniformly distributed throughout the composition.

[0027] In one embodiment, the composition contains EPDM as an elastomer, is essentially composed of EPDM, or is composed of EPDM. In this example, a corrosion inhibitor blend can be injected into or mixed with the EPDM rubber. The corrosion inhibitor blend may be present in the composition containing EPDM as an elastomer at a concentration of about 1 to 30% by weight. The corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or concentrations at any interval between any of these concentration ranges. In one embodiment, the corrosion inhibitor blend has a concentration of 20-22% in the composition. The corrosion inhibitor blend may have a concentration of 20% in the composition. The corrosion inhibitor blend may have a concentration of 22% in the composition. The concentration range of each corrosion inhibitor in the corrosion inhibitor blend may be within the concentration range according to Table 1 above, or within the sub-range concentration range according to Table 1 above.

[0028] In another embodiment, the composition contains silicone as an elastomer material, is essentially composed of silicone, or is composed of silicone. In this example, the corrosion inhibitor blend can be injected into or mixed with a silicone rubber compound. In this embodiment, the corrosion inhibitor blend has a concentration of 1 to 20% by weight of the final composition. The corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, or any interval between any concentration range. The corrosion inhibitor blend may have a concentration of 5 to 20% of the final composition. Since silicones have lower miscibility than, for example, EPDM, various binders can be used when injecting or mixing corrosion inhibitor blends into silicones. The concentration range of each corrosion inhibitor in the corrosion inhibitor blend may exist within the concentration ranges specified in Table 1 above, or within the sub-range concentration ranges specified in Table 1 above.

[0029] In one embodiment, the composition contains butyl as an elastomer material, is essentially composed of butyl, or is composed of butyl. In this example, a corrosion inhibitor blend can be injected into or mixed with the butyl rubber compound. In this embodiment, the corrosion inhibitor blend has a concentration of 1 to 30% by weight of the final composition. The corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or concentrations at any interval between any of these concentration ranges. The corrosion inhibitor blend may have a concentration of 5-22% of the final composition.

[0030] The concentration range of each corrosion inhibitor in the corrosion inhibitor blend may be within the concentration range specified in Table 1 above, or within the sub-range concentration range specified in Table 1 above.

[0031] In one embodiment, the composition comprises, essentially comprises, or consists of one of the following as an elastomer material: natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam.

[0032] One embodiment comprises an elastomer material 100 comprising, essentially comprising, or consisting of, an elastomer substance 200 and a corrosion inhibitor blend 300, as shown in Figures 1 and 2. The elastomer material may have elastic properties. In one embodiment, the elastic material 100 is deformable and flexible enough to return to its previous shape or form. This ability to deform and return to its original form may be referred to as having “memory.” The elastomer material may also be compressible but able to retain its shape well enough to still prevent contact between any surfaces inserted between them. For example, the elastomer material may have elastomer properties including, but are not limited to, compressible polymer rheology and maintaining elastomer strength, protecting against metal-to-metal contact, providing a reliable compression seal for voids and continuous pressure, and durability.

[0033] According to one embodiment, the elastomer material 100 can polarly bond with a metal surface based on the properties of the corrosion inhibitor blend 300. The elastomer material 100 may have the properties of the corrosion inhibitor blend 300, including but not limited to having polarity. As a result, the elastomer material 100 containing the corrosion inhibitor blend 300 can polarly bond with the metal surface 400 it contacts. The ability of the corrosion inhibitor blend 300 to polarly bond with the metal surface allows oxygen and moisture to be substituted between the elastomer material 100 and the metal 400, and similarly to lock itself onto the surface of the metal 400. According to one embodiment, the elastomer material 100 is corrosion-resistant to the metal it contacts. The elastomer material can provide more permanent corrosion protection than standard corrosion inhibitors. In one embodiment, the corrosion inhibitor blend has a high dielectric strength when injected into the elastomer material, which can enable insulation of the potential between the cathode and anode of two different metals, and insulation of the electrolyte-induced electron flow effect.

[0034] The corrosion inhibitor blend may have a concentration of about 1 to 30% by weight in the elastomer material. In one embodiment, the corrosion inhibitor blend has concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30% in the elastomer material, or any interval between any of these concentration ranges. In one embodiment, the corrosion inhibitor blend has a concentration of 20-22% in the elastomer material. According to one embodiment, the corrosion inhibitor blend is included in the elastomer material at a concentration of 20%. According to one embodiment, the corrosion inhibitor blend is included in the elastomer material at a concentration of 22%.

[0035] The corrosion inhibitor blend may contain one or more corrosion inhibitors selected from the group consisting of high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricants, bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt with bentonite, hydrogenated heavy naphtha (petroleum), dinonyl-calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate. In one embodiment, the corrosion inhibitor blend of the material may include a high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt with bentonite, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), and xylene. The corrosion inhibitor blend may also contain polarity-binding oil carriers for the corrosion inhibitors. The compositional percentage of each of the one or more corrosion inhibitors present in the corrosion inhibitor blend may be within the concentration ranges listed in Table 1, or within any subrange of the ranges according to Table 1.

[0036] The elastomer material may include one or more of the following: natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam materials, closed-cell foam materials, fine-cell foams, and chemically cross-linked polyethylene foams. According to one embodiment, the elastomer material is elastic. Elasticity can be achieved in the elastomer material itself. Elasticity can also be achieved by various additives and chemicals to make the elastic material have elastic properties and flexibility to the extent that it is deformable and can still return to the shape of its previous form.

[0037] In one embodiment, the material further comprises additives. The additives may be at least one of reinforcing fillers, bulking agents, oils, stabilizers, tackifiers, resins, curing agents, and other specially formulated corrosion inhibitor additives. Depending on the specific elastomer material selected, additives and chemicals may be included.

[0038] In one embodiment, the corrosion inhibitor blend replaces the standard non-polar paraffinic manufacturing oil in the material. In one embodiment, the elastomer material includes both the corrosion inhibitor blend and the standard non-polar manufacturing oil. In this example, the concentration of the corrosion inhibitor blend in the elastomer material containing the corrosion inhibitor blend is greater than the concentration of the corrosion inhibitor blend in the elastomer material containing both the corrosion inhibitor blend and the standard non-polar manufacturing oil. The combined concentration of the corrosion inhibitor blend and the standard non-polar manufacturing oil must not exceed a combined concentration that would impair the properties of the elastomer material.

[0039] According to one embodiment, the elastomer material is ethylene propylene diene monomer (EPDM) rubber. The corrosion inhibitor blend may be present in the elastomer material containing EPDM as the elastomer material at a concentration of about 1 to 30% by weight. The corrosion inhibitor blend may be present in the elastomer material at a concentration of about 5 to 22%. The corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or concentrations at any interval between any of these concentration ranges. In one embodiment, the corrosion inhibitor blend has a concentration of 20-22% in the elastomer material. The corrosion inhibitor blend may have a concentration of 20% in the elastomer material. The corrosion inhibitor blend may have a concentration of 22% in the elastomer material. The concentration range of each corrosion inhibitor in the corrosion inhibitor blend may be within the concentration range according to Table 1 above, or within the sub-range concentration range according to Table 1 above.

[0040] In another embodiment, the elastomer material is silicone. In this example, the corrosion inhibitor blend can be injected or mixed into the silicone rubber compound. In this embodiment, the corrosion inhibitor blend has a concentration of 1 to 20% by weight of the final elastomer material. The corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, or any interval between any of these concentration ranges. The corrosion inhibitor blend may have a concentration of 5 to 20% of the final material. For example, due to the properties of silicone, which are less miscible than EPDM, various binders can be used when injecting or mixing the corrosion inhibitor blend into the silicone. The concentration range of each corrosion inhibitor in the corrosion inhibitor blend may be within the concentration range specified in Table 1 above, or within the sub-range concentration range specified in Table 1 above.

[0041] According to one embodiment, the elastomer material is butyl. In this example, a corrosion inhibitor blend can be injected into or mixed with the butyl rubber compound. In this embodiment, the corrosion inhibitor blend has a concentration of 1 to 30% by weight of the elastomer material. The corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or concentrations at any interval between any of these concentration ranges. The corrosion inhibitor blend may have a concentration of 5-22% of the final material.

[0042] Elastomer materials, including elastomer materials and corrosion inhibitor blends, may encompass some or all of the characteristics of the individual corrosion inhibitors in the corrosion inhibitor blend, as well as the elastomer material itself. For example, elastomer materials may have elastomer properties including, but are not limited to, compressible polymer rheology and maintaining elastomer strength, protection against metal-to-metal contact, providing a reliable compression seal against voids and continuous pressure, and durability. Elastomer materials can also polarize with metal surfaces based on the properties of the corrosion inhibitor blend, thus enabling them to polarize with metal surfaces.

[0043] The elastomer material 100 may be in the form of a gasket or other type of mechanical seal, thereby filling the space between two or more mating surfaces. In one embodiment, the mating surfaces may be metal. When filling the space between two or more mating surfaces, the material can prevent leakage between the mating surfaces while under compressive force, though not always, often. In one embodiment, the elastomer material may be in the form of a gasket, or in other form that contacts a metal surface or two or more metal surfaces. The two or more metal surfaces may be similar metals. The two or more metal surfaces may be dissimilar metals.

[0044] The elastomer material may be in the form of a flat material, including but not limited to a sheet. The material may be in the form of a solid material that cannot be punched out from a sheet. Other non-limiting examples of elastomer material shapes include sheet gaskets, flange gaskets, ring gaskets, paper gaskets, cylinder head gaskets, and any other gasket shapes known in the art. In one embodiment, the elastomer material is a shape required for the mating of any two or more mating surfaces, filling in the irregularities of an imperfect mating. In one embodiment, the elastomer material is a shape required to mate any two or more mating surfaces to form a seal. In one embodiment, the elastomer material is a shape required for the elastomer material to contact a metal surface that provides corrosion protection. In one embodiment, the elastomer material may be in the form of other shapes, including, but not limited to, the edge of a drain.

[0045] In one embodiment, at least one of two or more mating surfaces is metal. In one embodiment, at least two of two or more mating surfaces are metal. In one embodiment, all of two or more mating surfaces are metal. In one embodiment, at least two or more mating surfaces are of similar metals. According to one embodiment, at least two or more metal surfaces are of dissimilar metals. In one embodiment, the elastomer material is in contact with a single metal surface. In one embodiment, the elastomer material prevents corrosion of the metal surface it is in contact with.

[0046] Essentially composed or composed of an elastomer material comprising an elastomer substance and at least one corrosion inhibitor or a blend of corrosion inhibitors can be formed into many shapes for marine use (Figure 4). Non-limiting examples include ship louvers, ship drain outlets 102, deck machinery base plates, electronic connections, pump housings, and other marine applications. In one embodiment, essentially composed or composed of an elastomer material comprising an elastomer substance and a blend of corrosion inhibitors can be formed into many shapes for use in highly corrosive marine applications. Elastomer materials can also be used for corrosion prevention applications in non-marine industries.

[0047] In one embodiment, all elements of the elastomer material, including the corrosion inhibitor blend, the elastomer material, and any additives, are uniformly distributed throughout the elastomer material. In one embodiment, the corrosion inhibitor blend is uniformly distributed throughout the elastomer material. Having a uniform distribution of the corrosion inhibitor allows the corrosion inhibitor blend to spread throughout the product.

[0048] The uniform distribution of the corrosion inhibitor blend, combined with the elastomer properties of the elastomer material, allows the corrosion inhibitor blend to bleed out of the material and come into contact with the metal surface, regardless of whether the elastomer material is stretched or relaxed. In both relaxed and stretched states, the corrosion inhibitor blend can be released or leached out and come into contact with the metal surface. For example, in the case of an elastomer material in the form of a gasket, no matter how much the gasket is compressed, its surface is always in contact with the corrosion inhibitor blend of the elastomer material. In one embodiment, bleeding out of the corrosion inhibitor blend means that the corrosion inhibitor blend is released from the elastomer material. When it bleeds out, the corrosion inhibitor blend may leave a residue on the metal surface. The residue may be in the form of a thin film. According to one embodiment, the thin film is a microfilm. Such a film remains on the metal surface and can prevent corrosion over a long period of time. The polar bonding of the corrosion inhibitor blend to the metal surface allows the corrosion inhibitor blend to latch onto the metal surface over a long period of time. In one embodiment, the corrosion inhibitor blend remains on the metal surface for 1 to 10 years. The corrosion inhibitor blend remains on the metal surface for a period of several days, several months, or several years. In one embodiment, the corrosion inhibitor layer may be removed in the presence of a high pH and / or detergent.

[0049] One embodiment comprises an elastomer material consisting of an elastomer substance, or comprising an elastomer material, wherein a butyl layer containing a corrosion inhibitor blend is laminated on the elastomer material. The butyl layer may be laminated on one side of the elastomer material, or the butyl layer may be laminated on two or more sides of the elastomer material. In one embodiment, the two sides are opposing sides. According to one embodiment, the butyl layer is laminated on the surface facing the elastomer material. The butyl layer is adhesive and can adhere to the elastomer material.

[0050] The elastomer material may be a gasket, a sheet, or any other form described herein. In such examples, the composition can be applied to one or both sides of such a gasket or sheet, especially if the surface is rough, more complex, and / or susceptible to large amounts of motion and vibration. One-sided application facilitates positioning and / or facilitates disassembly, for example, if required for periodic cleaning or maintenance. In one embodiment, the butyl layer is bonded to a metal surface. This makes it possible to hold the butyl layer in place on the metal surface, in particular, when there is no compressive force to hold the butyl layer containing the corrosion inhibitor blend in place.

[0051] According to one embodiment, the elastomer material of the elastomer material includes one or more of the following: natural rubber, polyisoprene, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam. According to one embodiment, the elastomer material of the elastomer material is ethylene propylene diene monomer (EPDM) rubber. According to one embodiment, the elastomer material is elastic.

[0052] In one embodiment, the elastomer material also includes a corrosion inhibitor blend. In this example, both the elastomer material and the butyl layer have the corrosion inhibitor blend. The concentration range of each corrosion inhibitor in the corrosion inhibitor blend may be within the concentration range according to Table 1 above, or within the sub-range concentration range according to Table 1 above.

[0053] The corrosion inhibitor blend may have a concentration of approximately 1 to 30% by weight in the elastomer material. The corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or any interval between any of these concentration ranges in the elastomer material. In one embodiment, the corrosion inhibitor blend has a concentration of 20-22% in the elastomer material. The corrosion inhibitor blend may have a concentration of 20% in the elastomer material. The corrosion inhibitor blend may have a concentration of 22% in the elastomer material.

[0054] The corrosion inhibitor blend may have a concentration of approximately 1–30% in the butyl layer. The corrosion inhibitor blend may have a concentration of 1–2%, 2–3%, 3–4%, 4–5%, 5–6%, 6–7%, 7–8%, 8–9%, 9–10%, 10–11%, 11–12%, 12–13%, 13–14%, 14–15%, 15–16%, 16–17%, 17–18%, 18–19%, 19–20%, 20–21%, 21–22%, 22–23%, 23–24%, 24–25%, 25–26%, 26–27%, 27–28%, 28–29%, 29–30%, or any interval between these concentrations in the butyl layer.

[0055] In one embodiment, the concentration of the corrosion inhibitor blend in the elastomer material is the same as the concentration of the corrosion inhibitor blend in the butyl layer. In another embodiment, the concentration of the corrosion inhibitor blend in the elastomer material is different from the concentration of the corrosion inhibitor blend in the butyl layer. The concentration of the corrosion inhibitor blend in the elastomer material may be higher than the concentration of the corrosion inhibitor blend in the butyl layer. The concentration of the corrosion inhibitor blend in the elastomer material may be lower than the concentration of the corrosion inhibitor blend in the butyl layer.

[0056] An elastomer material having a butyl layer containing a layered corrosion inhibitor blend on an elastomer material may encompass some or all of the characteristics of its individual components. The elastomer material and / or butyl layer may have a durable, compressible polymer rheology and strength that protects against, for example, metal-to-metal contact. The corrosion inhibitor blend itself can polarize with the metal surface, thereby preventing the effects of electrolysis on the metal in contact with the butyl layer, and thus preventing metal corrosion.

[0057] Elastomer materials having a butyl layer containing a corrosion inhibitor blend can be formed into many shapes for marine use. Non-limiting examples include ship louvers, ship drains, deck machinery base plates, electronic connectors, pump housings, and other marine applications. In one embodiment, the butyl layer-containing elastomer material can be formed into multiple shapes.

[0058] In one embodiment, a butyl layer containing a corrosion inhibitor blend can be applied to the elastomer material after manufacturing. The butyl layer containing the corrosion inhibitor blend is inherently sticky and may adhere to metal surfaces. In one example, the butyl layer containing the corrosion inhibitor blend may be directly laminated to the elastomer material at low temperature. The formed product can then be cut to the desired gasket shape using, for example, various different cutting techniques, as determined from the elastomer material by the gasket manufacturer.

[0059] According to one embodiment, a butyl layer having a corrosion inhibitor blend has a release liner on one side. The butyl layer can be manufactured in roll form for lamination onto a flat elastomer material such as EPDM. In one embodiment, the elastomer material such as EPDM is in roll form. In such an embodiment, the butyl layer having a corrosion inhibitor blend can be directly extruded onto the elastomer material or directly calendered. In one embodiment, the release liner is introduced after coating so that the composite material is formed directly without low-temperature lamination. It is not readily possible to produce a roll-formed elastomer material with a corrosion inhibitor injected using a butyl pressure-sensitive adhesive and low-temperature lamination. In such an embodiment, the liner may be introduced after coating in roll form.

[0060] One embodiment includes a method for preventing corrosion of a metal, essentially consisting of or comprising an elastomer material, which is placed in contact with the metal surface of the metal. The elastomer material may comprise an elastomer substance and a corrosion inhibitor blend, the corrosion inhibitor blend which can bleed out or seep out from the elastomer material and polarly bond with the metal. This allows oxygen and moisture to be replaced between the elastomer material and the metal, and also allows it to be fixed to the metal surface, providing more permanent corrosion protection than standard corrosion inhibitors. When on the metal surface, the corrosion inhibitor blend can isolate the potential between the cathode and anode of two different metals, and the electrolyte-induced electron flow effect of the electrolytic cycle. The elastomer material may further comprise a butyl layer containing the corrosion inhibitor blend on the surface of the elastomer material.

[0061] The corrosion inhibitor blend may have a concentration of about 1 to 30% by weight in the elastomer material. In one embodiment, the corrosion inhibitor blend may have concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or any interval between any concentration range. In one embodiment, the corrosion inhibitor blend has a concentration of 20-22% in the elastomer material. According to one embodiment, the corrosion inhibitor blend has a concentration of 20% in the elastomer material. According to one embodiment, the corrosion inhibitor blend has a concentration of 22% in the elastomer material.

[0062] The corrosion inhibitor blend may contain one or more corrosion inhibitors selected from the group consisting of high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricants, bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salts with bentonite, hydrogenated heavy naphtha, dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvents, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixtures, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate. The corrosion inhibitor blend may also contain a polarity-binding oil carrier for the corrosion inhibitors. In one embodiment, the corrosion inhibitor blend for the elastomer material may include a high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt, hydrogenated heavy naphtha, dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), and xylene. The compositional percentage of each of the one or more corrosion inhibitors present in the corrosion inhibitor blend may be within the concentration ranges listed in Table 1, or within any subrange of the ranges according to Table 1.

[0063] The elastomer material may include one or more of the following: natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam materials, closed-cell foam materials, fine-cell foams, and chemically cross-linked polyethylene foams. According to one embodiment, the elastomer material is elastic. Elasticity can be achieved in the elastomer material itself. Elasticity can also be achieved by various additives and chemicals to ensure that the elastic material has elastic properties and flexibility to the extent that it is deformable and can return to its previous shape. This ability to deform and return to its original shape can be said to have "memory."

[0064] According to one embodiment, the elastomer material further comprises additives. The additives may be at least one of reinforcing fillers, bulking agents, oils, stabilizers, tackifiers, resins, curing agents, and other specially formulated corrosion inhibitor additives. Depending on the specific elastomer material selected, additives and chemicals may be included.

[0065] This method may involve placing an elastomer material on or in contact with a metal surface. In one embodiment, the elastomer material is placed on the metal surface in an airtight and watertight manner. This method may involve interposing an elastomer material, preferably a corrosion-preventive gasket, between two metal surfaces, such as a flange or joint. In one embodiment, the elastomer material is inserted between the two metal surfaces in an airtight and watertight manner. In one embodiment, the two metal surfaces are of similar metal types. According to one embodiment, the two metal surfaces are of different metal types. Thus, the elastomer material can prevent bimetallic corrosion where the two metals come together. In one embodiment, three or more metals may come together, with the elastomer material interposed between their surfaces.

[0066] This method may further include using gaskets or other types of mechanical seals to form a seal that fills the space between two or more mating surfaces. In one embodiment, the mating surfaces may be metals. The metals may be dissimilar metals. When filling the space between two or more mating surfaces, the elastomer material can prevent leakage between the mating surfaces while under compressive force, though not always, often. The elastomer material may also bleed or seep onto the metal surface to protect the metal from corrosion.

[0067] In one embodiment, any one or more or all elements of an elastomer material, including a corrosion inhibitor blend, an elastomer material, and optional additives, can be uniformly distributed throughout the material. Having a uniform distribution of the corrosion inhibitor allows the corrosion inhibitor blend to spread throughout the product.

[0068] Non-limiting examples of settings in which different metals may be placed between elastomer materials, preferably corrosion-preventive gaskets, include hoses containing coolants, heaters, brakes, air conditioning, and air; HVAC systems, radiator seals; weatherstrips and sealing systems; molded gaskets and ducts; hydraulic wipers and seals; tire and tube applications; electrical insulation and jackets with medium to high dielectric strength; connectors, including tapes and wraps; conveyor belts, roll covers; corrosion prevention for hydraulic connectors; equipment baseplate insulation; kingpost and windlass base mounts; roof sheet insulation packing; window profile isolators and seals; extruded gaskets and related parts; ship louvers mounted on bulkheads; hatch mounts mounted on bulkheads and marine compartments; ship drains; building drains; electrolytic insulation packing seals; and storage or transport parts enclosed in packaging film. The uniform distribution of the corrosion inhibitor blend, combined with the elastomer properties of the elastomer material, allows the corrosion inhibitor blend to bleed out from the elastomer material and come into contact with the metal surface, regardless of whether the material is stretched or relaxed. In both relaxed and stretched states, the corrosion inhibitor blend can be released or leached out and come into contact with the metal surface. For example, in the case of a gasket-shaped material, no matter how much the gasket is compressed, the corrosion inhibitor blend is uniformly distributed throughout the elastomer material, so at least partially, its surface is always in contact with the corrosion inhibitor blend of the material.

[0069] In one embodiment, bleeding out of the corrosion inhibitor blend means that the corrosion inhibitor blend is released from the elastomer material. When bleeding out, the corrosion inhibitor blend may leave a residue on the metal surface. The residue may be in the form of a thin film. According to one embodiment, the thin film is a microfilm. Such a film remains on the metal surface and prevents corrosion for a long period of time. The polar bonding of the corrosion inhibitor blend to the metal surface allows the corrosion inhibitor blend to latch onto the metal surface for a long period of time. In one embodiment, the corrosion inhibitor blend remains on the metal surface for a period from one day to ten years. The corrosion inhibitor blend remains on the metal surface for a period of several days, several months, or several years. In one embodiment, the corrosion inhibitor layer may be removed in the presence of a high pH or detergent.

[0070] The elastomer material acts as a release film / release agent, allowing the fixture to remain in place where the elastomer material is sandwiched between non-corrosion surfaces. In one embodiment, the non-corrosion surfaces are at least one that does not corrode and does not need to be mechanically polished, scraped, or surface-polished to perform its function. In this case, when it is necessary to disassemble the fixture having the elastomer material, preferably a corrosion-resistant gasket, it can be easily removed and / or reinstalled. This may facilitate the replacement of individual components because not all metal pieces corrode.

[0071] A method for preventing corrosion further includes sealing the gap between two surfaces or joints. In one embodiment, the sealing occurs by the integration of the surfaces or joints. In one embodiment, the sealing further includes applying a compressive force to a corrosion-preventive gasket.

[0072] Elastomer materials, preferably corrosion-resistant gaskets, can be used for marine applications. Non-limiting examples include ship drains, ship louvers, deck machinery baseplates, electronic connections, pump housings, and other marine applications. In one embodiment, corrosion-resistant gaskets can be used in highly corrosive marine applications. Corrosion-resistant gaskets can also be used for corrosion protection applications in non-marine industrial settings. An example of a non-marine application is an elastomer material shaped like a building drain.

[0073] One embodiment includes a method for producing a corrosion-resistant elastomer material comprising an elastomer substance and a corrosion inhibitor blend. This method comprises, essentially comprises, or consists of mixing one or more corrosion inhibitors to form a corrosion inhibitor blend. The corrosion inhibitor blend may be in the form of a lubricant. The method may further include compounding the elastomer substance. In one embodiment, the method may include injecting the corrosion inhibitor blend together with the elastomer substance during compounding. The corrosion inhibitor blend can be compounded until a composite material is formed.

[0074] The corrosion inhibitor blend may be present in the elastomer material in an amount ranging from 1 to 30% by weight. In one embodiment, the corrosion inhibitor blend is present in the elastomer material in an amount ranging from 5 to 22%. In one embodiment, the corrosion inhibitor blend is present in the elastomer material at concentrations of 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, 9-10%, 10-11%, 11-12%, 12-13%, 13-14%, 14-15%, 15-16%, 16-17%, 17-18%, 18-19%, 19-20%, 20-21%, 21-22%, 22-23%, 23-24%, 24-25%, 25-26%, 26-27%, 27-28%, 28-29%, 29-30%, or any interval between any concentration range. In one embodiment, the corrosion inhibitor blend is present in the elastomer material in a range of 20-22% by weight.

[0075] This method further includes a step of curing the material. The material may be autoclaved and / or vulcanized, and the order of these steps can be rearranged. In one embodiment, the uncured elastomer material and corrosion inhibitor blend may be stored as a masterbatch before curing, autoclaving, and / or vulcanization.

[0076] In one embodiment, curing and / or vulcanization involves heating the elastomer material and shaping it to a form corresponding to any fixture requiring a corrosion-resistant elastomer material. Non-limiting examples of shapes include gaskets, sheets, or drain rims. In one embodiment, heating is performed by a heat tunnel, autoclave, or vulcanization method, or a variety of combinations thereof.

[0077] A method for producing an elastomer material comprising an elastomer substance and a corrosion inhibitor blend comprises mixing or compounding one or more corrosion inhibitor blends with the elastomer substance to form a composite material. In one embodiment, the compounding of the corrosion inhibitor blend is carried out after the elastomer itself has been compounded to an uncured paste-like consistency. In one embodiment, the compounding of the elastomer substance and the corrosion inhibitor blend results in an uncured paste-like consistency.

[0078] In one embodiment, a method for producing a composition comprising an elastomer material and a corrosion inhibitor blend further comprises adding one or more of the following additives: reinforcing fillers, bulking agents, oils, stabilizers, tackifiers, resins, curing agents, and other specially formulated corrosion inhibitor additives. The addition of additives can be done by combining the elastomer material alone or in a mixed blend of the elastomer material and a corrosion inhibitor.

[0079] In embodiments in which a corrosion inhibitor blend is injected into butyl, a method for producing a composition comprising an elastomer material and a corrosion inhibitor blend comprises adding one or more of the following additives to at least one of the butyl or elastomer material: reinforcing fillers, bulking agents, process oils, stabilizers, tackifiers, resins, curing agents, and other specially formulated corrosion inhibitor additives. The additives may be mixed with butyl alone or with a mixed mixture of butyl and the corrosion inhibitor.

[0080] In one embodiment, at least two specific mixing sequences of elastomers, corrosion inhibitors, and additives are used. The mixing process is a combination of one-pass and multi-pass heating and mixing. Temperature and time conditions can vary depending at least on the formulation, the raw materials used (e.g., whether they are in liquid or powder form), and the infrastructure (e.g., mixing capacity, paddle size, batch size, pump size, recirculation, bubbling, dispersion, kettle shape, and others). In one embodiment, the temperature is in the range of 15°C to 80°C. According to one embodiment, the temperature is in the range of ambient temperature to 80°C. The time used to mix and / or heat the sample can also vary considerably. In one embodiment, the time for mixing and / or heating the sample is in the range of 1 hour to 8 hours.

[0081] This method may further include one or more of molding, extrusion, shaping, or calendering. The calendering step can facilitate the smoothing and compression of all components during the mixing stage in which the raw materials and additives are introduced into a heated pair of rollers, preferably calender rollers. Calendering can be performed during the compounding of the elastomer material and the corrosion inhibitor blend, or during the compounding of the elastomer material, corrosion inhibitor blend, and additives. The calendering function smooths and compresses all components of the elastomer material, and preferably eliminates any dry / non-wet zones in the elastomer material into which the corrosion inhibitor blend has been injected, as well as other additives that eliminate any non-curable areas. In one embodiment, the method further includes a curing or vulcanization step.

[0082] In one embodiment, curing includes heating the composition and molding the composition into an elastomer material having a shape corresponding to any fitting requiring the elastomer material. Non-limiting examples of shapes include gaskets, sheets, or drain rims. In one embodiment, heating is performed by heat tunneling, autoclaving, vulcanization, or various combinations thereof.

[0083] The elastomer material may include one or more of the following: natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam materials, closed-cell foam materials, fine-cell foams, and chemically cross-linked polyethylene foams. According to one embodiment, the elastomer material is EPDM rubber.

[0084] One or more corrosion inhibitors in a corrosion inhibitor blend may be selected from the group consisting of high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricants, bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salts with bentonite, hydrogenated heavy naphtha, dinonyl-calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvents, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixtures, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate. The corrosion inhibitor blend may also contain a polarity-binding oil carrier for the corrosion inhibitors. In one embodiment, the corrosion inhibitor blend includes a high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt, hydrogenated heavy naphtha, dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), and xylene. In one embodiment, a lubricant is formed by mixing one or more corrosion inhibitors into the corrosion inhibitor blend.

[0085] A method for producing an elastomer material comprising an elastomer substance and a corrosion inhibitor blend may include forming a corrosion inhibitor blend. The formation of a corrosion inhibitor blend can be done by combining one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt, hydrogenated heavy naphtha, dinonyl-calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate. In one embodiment, the corrosion inhibitor blend is formed by combining a high-viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt with bentonite, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), and xylene. In one embodiment, a lubricant is formed by mixing one or more corrosion inhibitors into the corrosion inhibitor blend.

[0086] In one embodiment, the corrosion inhibitor blend can be introduced at a specific stage of mixing in a specific concentration range of 1 to 30% by weight of the elastomer material. The corrosion inhibitor blend can be introduced at a specific stage of mixing in a specific concentration range of 5 to 22% by weight. In one embodiment, the corrosion inhibitor blend can be introduced at a specific stage of mixing in a specific concentration range of 20 to 22% by weight. All components can fuse together to form a homogeneous elastomer material, including new desired design forms of functional elastomer materials. In one embodiment, the corrosion inhibitor blend is incorporated into the elastomer material and fully blended / mixed into the final uncured masterbatch composition.

[0087] In one embodiment, the mixing, compounding, and calendering of the corrosion inhibitor blend, elastomer material, and additives (if any) proceed in such a way that aggregates, clumps, and non-dispersed components are eliminated throughout the mixing and / or compounding stages. This can eliminate the possibility that dry / non-wet zones may eliminate areas of the mixed compound that cannot be cured.

[0088] In one embodiment, the corrosion inhibitor blend is formulated and blended before it is incorporated into the elastomer material. As shown in Figure 5, the elastomer material may be raw EPDM material. In such an example, propylene, ethylene, and diene monomers are polymerized in the presence of a catalyst according to Figure 5. Upon removal and recovery of the catalyst, as well as recovery of the monomers, the polymerized EPDM is mixed and / or incorporated with the corrosion inhibitor blend. The elastomer material, or more specifically EPDM in this example, may first be incorporated with all polymers and additives in a consistent manner where the elastomer material and additive formulation accepts the corrosion inhibitor blend into the untreated, uncured elastomer material. That is, the elastomer material formulation and the corrosion inhibitor blend formulation can be completed separately first, and then both the elastomer material and the corrosion inhibitor blend can be mixed and incorporated. In such an example, all components of the raw elastomer material are fully integrated and homogeneous before the corrosion inhibitor blend is introduced. This can be useful because elastomer materials such as EPDM may have many powder additives, such as carbon black and / or calcium carbonate, which must be blended completely and uniformly to prevent "dry spots." Based on at least such, the corrosion inhibitor blend can then be uniformly supported throughout the raw EPDM compound. The corrosion inhibitor blend may also include a corrosion-preventive polarity binding oil carrier blended with the corrosion inhibitor. The mixing is carried out over many cycles and then folded back into a calender. In this embodiment, both main components consist of their own specific formulations before being compounded together to form a new gasket material. In one embodiment, the elastomer material, or more specifically EPDM in this example, may first be compounded with the polymer, corrosion inhibitor blend, and all of the additives, which then form a raw, uncured elastomer material.

[0089] In one embodiment, the uncompounded mixed composition may be stored before curing and / or vulcanization.

[0090] Detailed explanation example:

[0091] 1. A composition comprising, essentially, an elastomer material and a corrosion inhibitor.

[0092] 2. The composition of Example 1, wherein the corrosion inhibitor blend is selected from one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillate, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate.

[0093] 3. Any one composition of Embodiments 1 to 2, wherein the elastomer material comprises at least one of natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomer, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam.

[0094] 4. The composition according to any one of Embodiments 1 to 3, wherein the elastomer material comprises ethylene propylene diene monomer (EPDM) rubber.

[0095] 5. Any one composition of Embodiments 1 to 4, wherein the percentage of each corrosion inhibitor in the corrosion inhibitor blend of one or more corrosion inhibitors is, if present, 25-75% for bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt containing bentonite, 1-10% for high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricant, 10-60% for hydrogenated heavy naphtha (petroleum), 5-35% for dinonyl calcium naphthalene sulfonate, 2-15% for calcium carbonate, 1-15% for hydrogenated light petroleum distillate, 0-40% for Stoddard solvent, 0.01-1% for ethylbenzene, 0.01-1% for naphthalene, and 0.01-1% for nonane. A composition containing 0.1-1% of the above, if present, 0.1-1% of pseudocumene (1,2,4-trimethylbenzene), if present, 0.1-1% of xylene, if present, 5-15% of the carboxy-imidazoline mixture, if present, 1-25% of barium carbonate, if present, 1-20% of dinonylnaphthalene sulfonic acid, if present, 1-30% of calcium dinonylnaphthalene sulfonic acid / carboxylate, or if present, 1-25% of zinc alkylnaphthalene sulfonic acid / carboxylate.

[0096] 6. A composition of any one of Embodiments 1 to 5, wherein one or more corrosion inhibitors of the corrosion inhibitor blend comprises a high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillate, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), and xylene.

[0097] 7. Any one of the compositions of Embodiments 1 to 6, wherein a corrosion inhibitor blend is present in the composition in an amount ranging from 1 to 30% by weight.

[0098] 8. Any one of Embodiments 1 to 7, wherein a corrosion inhibitor blend is present in the composition in an amount ranging from 20 to 22% by weight.

[0099] 9. The composition according to any one of Embodiments 1 to 8, further comprising a reinforcing filler, a bulking agent, an oil, a stabilizer, a curing agent, and other specially formulated corrosion inhibitor additives.

[0100] 10. Elastomer material comprising, essentially comprising, or consisting of a corrosion inhibitor blend and an elastomer substance.

[0101] 11. An elastomer material of Embodiment 10, wherein a corrosion inhibitor blend is present in the material in the range of 1 to 30 wt / wt%.

[0102] 12. An elastomer material, one of embodiments 10 to 11, wherein the corrosion inhibitor mixes with a metal and polar bonds.

[0103] 13. An elastomer material according to any one of embodiments 10 to 12, wherein the elastomer material prevents corrosion of the metal through contact between the elastomer material and the metal.

[0104] 14. An elastomer material according to any one of Examples 10 to 13, wherein the corrosion inhibitor blend comprises one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C 20 to 50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxyimidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate.

[0105] 15. An elastomer material according to any one of Embodiments 10 to 14, wherein the corrosion inhibitor blend comprises a high viscosity petroleum C 20 to 50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt, hydrogenated heavy naphtha (petroleum), naphthalene sulfonate dinonyl-calcium salt, calcium carbonate, hydrogenated light petroleum distillate, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), and xylene.

[0106] 16. An elastomer material according to any one of Embodiments 10 to 15, wherein the elastomer material comprises at least one of natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomer, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, rubber, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam.

[0107] 17. An elastomer material in any one of embodiments 10 to 16, wherein the elastomer substance comprises ethylene propylene diene monomer (EPDM) rubber.

[0108] 18. An elastomer material according to any one of Embodiments 10 to 17, wherein the percentage of each corrosion inhibitor in one or more corrosion inhibitors in the corrosion inhibitor blend is, if present, 25 to 75% relative to bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt having bentonite, if present, 1 to 10% relative to high viscosity petroleum C 20 to 50 hydrogenated neutral oil-based lubricant, if present, 10 to 60% relative to hydrogenated heavy naphtha (petroleum), if present, 5 to 35% relative to dinonyl calcium naphthalene sulfonate, if present, 2 to 15% relative to calcium carbonate, if present, 1 to 15% relative to hydrogenated light petroleum distillate, if present, 0 to 40% relative to Stoddard solvent, if present, 0.01 to 1% relative to ethylbenzene, if present, 0.01 to 1% relative to naphthalene, if present, 0.1% relative to nonane An elastomer material containing ~1%, if present, 0.1~1% relative to pseudocumene (1,2,4-trimethylbenzene), if present, 0.1~1% relative to xylene, if present, 5~15% relative to carboxy-imidazoline mixture, if present, 1~25% relative to barium carbonate, if present, 1~20% relative to dinonylnaphthalene sulfonic acid, if present, 1~30% relative to dinonylnaphthalene sulfonic acid / calcium carboxylate, or if present, 1~25% relative to alkylnaphthalene sulfonic acid / zinc carboxylate.

[0109] 19. An elastomer material according to any one of embodiments 10 to 18, wherein a corrosion inhibitor blend is present in the range of 5 to 22 wt / wt%.

[0110] 20. An elastomer material according to any one of embodiments 10 to 19, wherein a corrosion inhibitor blend is present in the range of 20 to 22 wt / wt%.

[0111] 21. An elastomer material according to any one of Embodiments 10 to 20, wherein a corrosion inhibitor blend is present in 20% or 22% by weight / weight.

[0112] 22. An elastomer material according to any one of Embodiments 10 to 21, further comprising a reinforcing filler, a spreading filler, oil, a stabilizer, a curing agent, and other specially formulated corrosion inhibitor additives.

[0113] 23. In any one of the elastomer materials from Embodiments 10 to 22, the corrosion inhibitor blend is evenly distributed throughout the corrosion-resistant material.

[0114] 24. An elastomer material comprising any one of embodiments 10 to 23, wherein the corrosion inhibitor blend bleeds out from the elastomer material and polarizes with the metal.

[0115] 25. An elastomer material according to any one of embodiments 10 to 24, wherein, whether the elastomer material is compressed or relaxed, the corrosion inhibitor blend bleeds out from the elastomer material and polar bonds with the metal at any thickness of the elastomer material.

[0116] 26. An elastomer material of any one of embodiments 10 to 25, which may take the form of at least one of the following: sheet gaskets, flange gaskets, ring gaskets, paper gaskets, cylinder head gaskets, molded gaskets, extruded gaskets and related parts, hoses, weatherstrips, sealing systems, hydraulic wipers, seals, connectors, conveyor belts, roll covers, kingposts and windless base mounts, roof sheet isolation packings, window profile isolators and seals, ship louvers mounted on bulkheads, hatch mounts mounted on bulkheads and ship compartments, drain edges, ship drains, building drains, tire and tube applications, electrical insulation and jackets with medium to high dielectric strength, electrolytic isolation packing seals, and parts for storage or transport enclosed in packaging film.

[0117] 27. An elastomer material according to any one of embodiments 10 to 26, further comprising a butyl layer on the surface of the elastomer material, wherein the butyl layer comprises a corrosion inhibitor blend.

[0118] 28. A method for making an elastomer material which essentially consists of or comprises an elastomer material and a corrosion inhibitor blend.

[0119] 29. The method of Embodiment 28, further comprising mixing one or more corrosion inhibitors to form a corrosion inhibitor blend.

[0120] 30. Any one of embodiments 28 to 29, further comprising incorporating an elastomer material.

[0121] 31. Any one of the embodiments 28 to 30, further comprising injecting a corrosion inhibitor blend together with the elastomer material during compounding.

[0122] 32. Any one of embodiments 28 to 31, further comprising curing the composite material to form an elastomer material.

[0123] 33. Any one of embodiments 28 to 32, wherein the corrosion inhibitor blend is present in the elastomer material in a range of 1 to 30 wt / wt%.

[0124] 34. The corrosion inhibitor is mixed with a metal and polar bonds in any one of the embodiments 28 to 33.

[0125] 35. The elastomer material prevents corrosion of the metal through contact between the elastomer material and the metal, according to any one of embodiments 28 to 34.

[0126] 36. A method of any one of Embodiments 28 to 35, wherein the corrosion inhibitor blend comprises one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C 20 to 50 hydrogenated neutral oil-based lubricants, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salts, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate.

[0127] 37. One of the methods of Embodiments 28 to 36, wherein the percentage of each corrosion inhibitor in the corrosion inhibitor blend of one or more corrosion inhibitors is, if present, 25 to 75% for bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt containing bentonite, if present, 1 to 10% for high viscosity petroleum C 20 to 50 hydrogenated neutral oil-based lubricants, if present, 10 to 60% for hydrogenated heavy naphtha (petroleum), if present, 5 to 35% for dinonyl calcium naphthalene sulfonate, if present, 2 to 15% for calcium carbonate, if present, 1 to 15% for hydrogenated light petroleum distillates, if present, 0 to 40% for Stoddard solvent, if present, 0.01 to 1% for ethylbenzene, if present, 0.01 to 1% for naphthalene, if present, for nonane The method involves the following concentrations: 0.1-1% for the first component, 0.1-1% for pseudocumene (1,2,4-trimethylbenzene) if present, 0.1-1% for xylene if present, 5-15% for carboxy-imidazoline mixture if present, 1-25% for barium carbonate if present, 1-20% for dinonylnaphthalene sulfonic acid if present, 1-30% for dinonylnaphthalene sulfonic acid / calcium carboxylate if present, or 1-25% for alkylnaphthalene sulfonic acid / zinc carboxylate if present.

[0128] 38. A method comprising mixing and injecting an elastomer material and a corrosion inhibitor blend according to any one of embodiments 28 to 37, further comprising adding one or more of the following additives: reinforcing fillers, bulking agents, process oils, stabilizers, curing agents, and other specially formulated corrosion inhibitor additives.

[0129] 39. Any one of embodiments 28 to 38, further comprising calendering an elastomer material using a heating roller that includes one-pass or multi-pass heating and mixing.

[0130] 40. Any one of embodiments 28 to 39, wherein the calendering process is performed during the compounding process.

[0131] 41. Any one of embodiments 28 to 40, wherein a corrosion inhibitor blend and additives are added during the calendering process.

[0132] 42. Calendering is performed in any one of the embodiments 28 to 41, facilitating the smoothing and compression of all components of the corrosive material, preferably eliminating any dry / non-wet zones to eliminate non-curable areas of the corrosive material into which the corrosion inhibitor blend and other additives have been injected.

[0133] 43. Any one of embodiments 28 to 42, further comprising molding an elastomer material containing a corrosion inhibitor blend and an elastomer substance into a gasket-like shape before curing.

[0134] 44. Any one of the embodiments 28 to 43, wherein curing comprises heating a composite material comprising a corrosion inhibitor blend and an elastomer material.

[0135] 45. A method for preventing metal corrosion, comprising bringing an elastomer material into contact with the metal.

[0136] 46. ​​The method of Embodiment 45, wherein the material consists of a blend of an elastomer and a corrosion inhibitor.

[0137] 47. The corrosion inhibitor blend is present in the elastomer material in a range of 1 to 30 wt / wt%, in any one of the embodiments 45 to 46.

[0138] 48. The corrosion inhibitor blend bleeds out from the elastomer material and forms a polar bond with the metal, in any one of embodiments 45 to 47.

[0139] 49. A method of any one of Embodiments 45 to 48, wherein the corrosion inhibitor blend comprises one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C 20 to 50 hydrogenated neutral oil-based lubricants, bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt with bentonite, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate.

[0140] 50. One of the methods of Embodiments 45 to 49, wherein the percentage of each corrosion inhibitor in one or more corrosion inhibitors in the corrosion inhibitor blend is, if present, 25 to 75% for bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt having bentonite, if present, 1 to 10% for high viscosity petroleum C 20 to 50 hydrogenated neutral oil-based lubricants, if present, 10 to 60% for hydrogenated heavy naphtha (petroleum), if present, 5 to 35% for dinonyl calcium naphthalene sulfonate, if present, 2 to 15% for calcium carbonate, if present, 1 to 15% for hydrogenated light petroleum distillates, if present, 0 to 40% for Stoddard solvent, if present, 0.01 to 1% for ethylbenzene, if present, 0.01 to 1% for naphthalene, if present, for nonane A method in which the amounts are 0.1-1% for the above, 0.1-1% for pseudocumene (1,2,4-trimethylbenzene) if present, 0.1-1% for xylene if present, 5-15% for carboxy-imidazoline mixture if present, 1-25% for barium carbonate if present, 1-20% for dinonylnaphthalene sulfonic acid if present, 1-30% for dinonylnaphthalene sulfonic acid / calcium carboxylate if present, or 1-25% for alkylnaphthalene sulfonic acid / zinc carboxylate if present.

[0141] 51. Any one of the methods of Embodiments 45 to 50, wherein the elastomer material comprises at least one of natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomer, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, rubber, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam.

[0142] 52. Any one of Embodiments 45 to 51, wherein the elastomer material comprises ethylene propylene diene monomer (EPDM) rubber and a corrosion inhibitor blend is present in the material in the range of 20 to 22 wt / wt%.

[0143] 53. Any one of embodiments 45 to 52, wherein the arrangement of the elastomer material is on a metal surface.

[0144] 54. The arrangement of the elastomer material is between two metal surfaces, and each of the metals on the two metal surfaces is similar, in any one of embodiments 45 to 52.

[0145] 55. The arrangement of the elastomer material is carried out between two metal surfaces, wherein each of the two metal surfaces is different from one another, in any one of embodiments 45 to 52.

[0146] 56. Any one of embodiments 45 to 55, further comprising sealing the gap between two metal surfaces.

[0147] 57. One of the embodiments 45 to 56, wherein sealing is performed by two metal surfaces acting together to exert a compressive force on the material.

[0148] 58. Use of an elastomer material for preventing corrosion of metal parts, wherein the corrosion-preventive material essentially comprises or comprises a blend of an elastomer substance and a corrosion inhibitor, and the corrosion inhibitor blend comprises one or more corrosion inhibitors.

[0149] 59. Use of an elastomer material in embodiment 58, in which the elastomer material prevents corrosion of the metal surface it comes into contact with.

[0150] 60. Use of any one of the elastomer materials of Examples 58-59, wherein the corrosion inhibitor blend comprises one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate.

[0151] 61. Use of an elastomer material to prevent corrosion of any one of the metal parts of Examples 58 to 60, wherein the elastomer material comprises at least one of natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomer, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, rubber, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam.

[0152] 62. Use of any one of the elastomer materials from Examples 58 to 61, wherein the elastomer substance contains ethylene propylene diene monomer (EPDM) rubber.

[0153] 63. Use of any one elastomer material from Examples 58-62, wherein the percentage of each of one or more corrosion inhibitors in the corrosion inhibitor blend in the composition is 25-75% for bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt having bentonite, 1-10% for high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricant, 10-60% for hydrogenated heavy naphtha (petroleum), 5-35% for dinonyl calcium naphthalene sulfonate, 2-15% for calcium carbonate, 1-15% for hydrogenated light petroleum distillate, 1-40% for Stoddard solvent, 0.01-1% for ethylbenzene, 0.01-1% for naphthalene, and 0.1% for nonane. Use of elastomer materials, in amounts of ~1%, 0.1-1% of pseudocumene (1,2,4-trimethylbenzene) if present, 0.1-1% of xylene if present, 5-15% of carboxy-imidazoline mixture if present, 1-25% of barium carbonate if present, 1-20% of dinonylnaphthalene sulfonic acid if present, 1-30% of dinonylnaphthalene sulfonic acid / calcium carboxylate if present, or 1-25% of alkylnaphthalene sulfonic acid / zinc carboxylate if present.

[0154] 64. Use of any one of the elastomer materials of Examples 58-63, wherein the corrosion inhibitor blend contains, essentially contains, or consists of, a high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt, hydrogenated heavy naphtha (petroleum), naphthalene sulfonate dinonyl-calcium salt, calcium carbonate, hydrogenated light petroleum distillate, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene.

[0155] 65. Use of any one of the elastomer materials of embodiments 58 to 64 to place a corrosion-preventive material on the surface of a metal part.

[0156] 66. Use of any one of the elastomer materials of embodiments 58 to 65 to place a corrosion-preventive material between two surfaces or joints of metal parts. [Examples]

[0157] Example 1

[0158] A new flange 101 was assembled with gasket material 102 containing EPDM and a corrosion inhibitor blend, and subjected to an accelerated corrosion test. The corrosion inhibitor blend was concentrated at 20–22% by weight of the final gasket material (Figures 6A and 6B). The flange-gasket assembly was immersed in 32% hydrochloric acid (HCl) at 21°C for 24 hours. Figure 6C shows the immersion in HCl and further shows the direct HCl vapor in contact with the upper half of the immersed flange-gasket assembly. The flange-gasket assembly was then transferred and immersed in a high-salinity saline solution at 21°C for 24 hours, at the same or similar level as the immersion in the concentrated HCl solution. The high-salinity solution was 500 g of sea salt per 1 kg of aqueous solution. In comparison, seawater contains an average of 35 g of salt per 1 kg of water, and Dead Sea water contains an average of approximately 330 g of salt per 1 kg of water. After 24 hours in a high saline solution, the flange-gasket assembly was removed and dried for 24 hours, where a salt layer formed on the surface, as shown in Figure 6E. Figure 6E further illustrates the corrosion of flange 102, where the immersed portion exhibits a greater degree of corrosion than the portion exposed only to concentrated HCl vapor. Next, flange 101 was opened and gasket 102 was removed to reveal the inner metal surface of flange 101 in contact with gasket 102. These protected surfaces appeared new and showed no degree of corrosion after immersion treatment in concentrated HCl and high saline solutions. This treatment of the metal flange demonstrates how resistant the gasket material, including EPDM and a corrosion inhibitor blend, is to corrosion.

[0159] Although the present invention has been described in relation to its specific embodiments, certain modifications and equivalents will be obvious to those skilled in the art and are intended to be included within the scope of the invention.

Claims

1. An elastomer material comprising an elastomer substance and a blend of corrosion inhibitors, Here, The corrosion inhibitor blend is present in the material in the range of 1 to 30% by weight; The corrosion inhibitor blend has polar bonding with the metal; and Elastomer materials prevent metal corrosion through contact between the elastomer material and the metal. material.

2. The elastomer material according to claim 1, wherein the corrosion inhibitor blend comprises one or more corrosion inhibitors selected from the group consisting of a high viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethyl quaternary ammonium salt, hydrogenated heavy naphtha, dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate.

3. The percentage of each of the one or more corrosion inhibitors in the aforementioned corrosion inhibitor blend is, if present, 25-75% relative to bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt containing bentonite, if present, 1-10% relative to high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricant, if present, 10-60% relative to hydrogenated heavy naphtha (petroleum), if present, 5-35% relative to dinonyl calcium naphthalene sulfonate, if present, 2-15% relative to calcium carbonate, if present, 1-15% relative to hydrogenated light petroleum distillate, if present, 0-40% relative to Stoddard solvent, if present, 0.01-1% relative to ethylbenzene, if present, 0.01-1% relative to naphthalene, if present, 0.1-1% relative to nonane, if present, pseudocumene (1,2, The material according to claim 2, which is present in an amount of 0.1 to 1% relative to 4-trimethylbenzene, and if present, 0.1 to 1% relative to xylene, if present, 5 to 15% relative to the carboxy-imidazoline mixture, if present, 1 to 25% relative to barium carbonate, if present, 1 to 20% relative to dinonylnaphthalene sulfonic acid, if present, 1 to 30% relative to dinonylnaphthalene sulfonic acid / calcium carboxylate, or if present, 1 to 25% relative to alkylnaphthalene sulfonic acid / zinc carboxylate.

4. The elastomer material according to claim 1, wherein the elastic material is a substance comprising at least one of natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomer, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, microcellular foam, and chemically crosslinked polyethylene foam.

5. The elastomer material according to claim 4, wherein the elastomer substance comprises ethylene propylene diene monomer (EPDM) rubber.

6. The elastomer material according to claim 1, wherein the corrosion inhibitor blend is present in the material in an amount of 20 to 22% by weight.

7. The elastomer material according to claim 1, wherein the corrosion inhibitor blend is uniformly dispersed throughout the elastomer material.

8. The elastomeric material according to claim 1, wherein the corrosion inhibitor blend bleeds from the elastomeric material and forms polar bonds with the metal.

9. The elastomeric material according to claim 8, wherein the corrosion inhibitor blend bleeds from the elastomeric material and polar bonds with the metal at any thickness of the elastomeric material, regardless of whether the elastomeric material is compressed or relaxed.

10. The elastomer material according to claim 1, Elastomer materials may take the form of at least one of the following: sheet gaskets, flange gaskets, ring gaskets, paper gaskets, cylinder head gaskets, molded gaskets, extruded gaskets and related parts, hoses, weatherstrips, sealing systems, hydraulic wipers, seals, connectors, conveyor belts, roll covers, kingposts and windless base mounts, roof sheet isolation packings, window profile isolators and seals, ship louvers mounted on bulkheads, hatch mounts mounted on bulkheads and ship compartments, drain edges, ship drains, building drains, tire and tube applications, electrical insulation and jackets with medium to high dielectric strength, electrolytic isolation packing seals, and parts in storage or transport packaged in film. Elastomer material.

11. The elastomer material according to claim 1, further comprising a reinforcing filler, a spreading filler, oil, a stabilizer, a curing agent, and other specially formulated corrosion inhibitor additives.

12. The elastomer material according to claim 1, further comprising a butyl layer on the surface of the elastomer material, wherein the butyl layer comprises the corrosion inhibitor blend.

13. A method for producing an elastomer material comprising an elastomer substance and a corrosion inhibitor blend, the method comprising the following steps: A process of mixing one or more corrosion inhibitors to form a corrosion inhibitor blend; The process of compounding elastomer materials; and A process of injecting a corrosion inhibitor blend into an elastomer material during compounding to form a composite material; and A process of curing composite materials to form elastomer materials, Here, The corrosion inhibitor blend is present in the elastomer material in a range of 1 to 30 wt / wt%; The corrosion inhibitor blend forms polar bonds with the metal; and Elastomer materials prevent metal corrosion through contact between the elastomer material and the metal. method.

14. A method for producing the elastomer material described in claim 13, The corrosion inhibitor blend comprises one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C20-50 hydrogenated neutral oil-based lubricant, bentonite and bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (124-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate. The percentage of each corrosion inhibitor in one or more corrosion inhibitors in a corrosion inhibitor blend is, if present, 25-75% for bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salts containing bentonite, 1-10% for high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricants, 10-60% for hydrogenated heavy naphtha (petroleum), 5-35% for dinonyl calcium naphthalene sulfonate, 2-15% for calcium carbonate, 1-15% for hydrogenated light petroleum distillates, 0-40% for Stoddard solvents, 0.01-1% for ethylbenzene, 0.01-1% for naphthalene, and nonanes. For all of these, the concentration is 0.1–1%, for pseudocumene (1,2,4-trimethylbenzene) it is 0.1–1%, for xylene it is 0.1–1%, for carboxy-imidazoline mixtures it is 5–15%, for barium carbonate it is 1–25%, for dinonylnaphthalene sulfonic acid it is 1–20%, for dinonylnaphthalene sulfonic acid / calcium carboxylate it is 1–30%, or for alkylnaphthalene sulfonic acid / zinc carboxylate it is 1–25%. method.

15. The method according to claim 13, wherein the corrosion inhibitor blend is compounded with and injected with an elastomer material, further comprising adding one or more of the following additives: reinforcing fillers, bulking agents, process oils, stabilizers, curing agents, and other specially formulated corrosion inhibitor additives.

16. Furthermore, the process includes calendering the elastomer material with a heated roller that involves one or more passes of heating and mixing. Here, The calendaring process is performed during the blending process. Corrosion inhibitor blends and additives are added during the calendering process. Calendering promotes the smoothing and compression of all components of the corrosion inhibitor, preferably eliminating any dry / non-wet zones and removing any uncurable areas of the corrosion inhibitor blend and other additives. The method according to claim 13.

17. Furthermore, the elastomer material containing a corrosion inhibitor blend and an elastomer substance is molded into a gasket-like shape before curing; and Curing involves heating a composite material containing a corrosion inhibitor blend and an elastomer material. The method according to claim 13

18. Arranging the elastomer material in contact with the metal, Here The elastomer material contains an elastomer substance and a corrosion inhibitor blend. The corrosion inhibitor blend is present in the elastomer material in a range of 1 to 30 wt / wt%; and The corrosion inhibitor blend leaches (blends) from the elastomer material and forms polar bonds with the metal. Methods to prevent metal corrosion.

19. A corrosion prevention method according to claim 18, The corrosion inhibitor blend comprises one or more corrosion inhibitors selected from the group consisting of high viscosity petroleum C20-50 hydrogenated neutral oil-based lubricants, bentonite and bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salt, hydrogenated heavy naphtha (petroleum), dinonyl calcium naphthalene sulfonate, calcium carbonate, hydrogenated light petroleum distillates, Stoddard solvent, ethylbenzene, naphthalene, nonane, pseudocumene (1,2,4-trimethylbenzene), xylene, carboxy-imidazoline mixture, barium carbonate, dinonylnaphthalene sulfonic acid, calcium dinonylnaphthalene sulfonate / carboxylate, or zinc alkylnaphthalene sulfonate / carboxylate; and The percentage of each corrosion inhibitor in one or more corrosion inhibitors in a corrosion inhibitor blend is, if present, 25-75% for bis(hydrogenated tallow alkyl)dimethylquaternary ammonium salts containing bentonite, 1-10% for high viscosity petroleum C 20-50 hydrogenated neutral oil-based lubricants, 10-60% for hydrogenated heavy naphtha (petroleum), 5-35% for dinonyl calcium naphthalene sulfonate, 2-15% for calcium carbonate, 1-15% for hydrogenated light petroleum distillates, 0-40% for Stoddard solvents, 0.01-1% for ethylbenzene, 0.01-1% for naphthalene, and nonanes. For all of these, the concentration is 0.1–1%, for pseudocumene (1,2,4-trimethylbenzene) it is 0.1–1%, for xylene it is 0.1–1%, for carboxy-imidazoline mixtures it is 5–15%, for barium carbonate it is 1–25%, for dinonylnaphthalene sulfonic acid it is 1–20%, for dinonylnaphthalene sulfonic acid / calcium carboxylate it is 1–30%, or for alkylnaphthalene sulfonic acid / zinc carboxylate it is 1–25%. method.

20. The elastomer material includes at least one of the following: natural rubber, polyisoprene, butyl rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-based fluoroelastomers, fluorosilicone, nitrile butadiene rubber, saturated nitrile butadiene, silicone rubber (SI, gum, and liquid), styrene butadiene, urethane rubber, polyurethane, polyurea, open-cell foam material, closed-cell foam material, fine-cell foam, and chemically cross-linked polyethylene foam. The method according to claim 18.

21. The elastomer material contains ethylene propylene diene monomer (EPDM) rubber, and the corrosion inhibitor blend is present in the elastomer material in the range of 20–22% by weight. The method according to claim 20.

22. The arrangement of the elastomer material is on or between two metal surfaces, and the metals on the two metal surfaces are similar or dissimilar. The method according to claim 18.

23. Furthermore, the process includes a step of sealing the gap between the two metal surfaces, where sealing occurs when the two metal surfaces are joined and a compressive force is applied. The method according to claim 22.

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