Aerosol Coating Viscosity Control for Uniform Corrosion Protection
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Solution Overview
Problem
Current aerosol formulations for corrosion inhibition on metallic surfaces are ineffective due to high viscosity, leading to non-uniform coatings when dispensed from conventional aerosol cans, as they fail to atomize properly and require multiple coats.
Innovation Solution
A quick-drying aerosol composition comprising an emulsion of polyvinyl lower acyl esters, poly (lower alkyl) acrylates, or poly (lower alkyl) methacrylates with thickening agents, plasticizers, and a non-aqueous solvent, optimized for atomization and compatibility with propellants, allowing for uniform and efficient application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric corrosion inhibiting formulations are dispensed through aerosol dispensers, then corrosion protection is provided, but the coating is non-uniform and ineffective due to high viscosity prohibiting proper atomization
Solution Approach 1:
The patent modifies the physical and chemical parameters of the polymeric formulation by incorporating specific solvents (acetone, isopropanol, butyl acetate) in controlled amounts to reduce viscosity. The resin content is optimized to 10-40% by weight, and plasticizers are added to adjust the flow characteristics, enabling the high-viscosity polymer to be properly atomized through aerosol dispensers while maintaining corrosion protection efficacy.
Solution Approach 2:
The invention creates a composite aerosol formulation that combines polymeric resin (for corrosion inhibition), solvents (for viscosity reduction and atomization), plasticizers (for flow improvement), and propellants (for aerosol generation). This composite system enables the polymer to be dispensed as a uniform aerosol coating while retaining its protective function.
2Ease of operation
If conventional aerosol valves are used with high viscosity polymer formulations, then the formulation can be dispensed, but proper atomization is prohibited resulting in non-uniform coating
Solution Approach 1:
The patent changes the rheological parameters of the formulation by adding solvents and plasticizers, reducing the viscosity to a range that allows conventional aerosol valves to function properly. The viscosity is adjusted so the polymer can flow through the valve and atomize into fine droplets, achieving both ease of dispensing and atomization quality.
3Reliability
If multiple coatings are applied to achieve adequate coverage, then sufficient protection is provided, but the application process becomes time-consuming and less efficient
Solution Approach 1:
The optimized formulation parameters (resin content 10-40%, controlled viscosity through solvents and plasticizers) enable a single coating application to achieve adequate coverage and protection. The improved atomization and flow characteristics ensure uniform distribution in one pass, eliminating the need for multiple applications and increasing application efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables a smooth, uniform, and strippable coating that effectively inhibits corrosion on metallic substrates, adhering well to surfaces while being easily removable, overcoming the limitations of existing formulations.
Implementation Method 1
a propellant in an amount sufficient to propel the coating composition through the valve and nozzle
Implementation Method 2
dispensed from an aerosol spray device... droplets of the composition are adapted to be discharged from an aerosol spray device
Implementation Method 3
an emulsion of a resin... the coating adhering well to surfaces while being easily removable
Implementation Method 4
for inhibiting corrosion on metallic surfaces... effectively inhibits corrosion on metallic substrates
Implementation Method 5
a plasticizer in an amount of 1 wt % to 15 wt % compatible with the resin... a quick drying aerosol composition... strippable coating
Data Source
AI summary
A quick drying aerosol composition for coating a metal substrate for inhibiting corrosion, wherein droplets of the composition are adapted to be discharged from an aerosol spray device, the aerosol composition comprises: an emulsion of a resin in an amount in the range of 10 wt % to 60 wt % selected from the group consisting of polyvinyl lower acyl esters in which the acyl has from two to five carbon atoms, poly (lower alkyl) acrylates in which the alkyl has from one to four carbon atoms, poly (lower alkyl) methacrylates in which the alkyl has from one to four carbon atoms, and copolymers thereof; one or more 100 thickening or anti-caking agents in amount in the range of 0.5 wt % to 7 wt %; a plasticizer in an amount in the range of 1 wt % to 15 wt % compatible with the resin; and a non-aqueous carrier/solvent in an amount 5 wt % to 35 wt %.