Alkyl Silicate Anti-Rust Coating for 10 µm Weldable Films
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Solution Overview
Problem
Existing anti-rust coatings struggle to form a thin film with a dry film thickness of 10 µm or less using conventional applicators without increasing environmental load or compromising weldability and anticorrosive properties, and they often result in weld defects like pits and blow holes during welding.
Innovation Solution
An anti-rust coating composition comprising alkyl silicate condensate, zinc powder, and specific pigments with a controlled mass ratio and pigment volume concentration, allowing for a long pot life and formation of a thin film with excellent weldability and anticorrosive properties without dilution with organic solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the discharge flow rate of the primary anti-rust coating is decreased to form a thin film, then the dry film thickness can be reduced to 10 μm or less, but a uniform coating film cannot be formed because the coating cannot be stably applied
Solution Approach 1:
The invention changes the chemical composition parameters of the coating, specifically using siloxane binder with 70-90 mass% SiO2 content and controlling the Zn/SiO2 mass ratio to 10-50, to enable stable thin film formation at 10 μm or less thickness
Solution Approach 2:
The invention uses a composite coating system combining siloxane binder with specific zinc powder particle sizes (3-15 μm) and controlled Zn/SiO2 mass ratio to achieve both thin film thickness and uniform application stability
2Volume of moving object
If the primary anti-rust coating is diluted with a large amount of organic solvent to reduce nonvolatile content for thin film formation, then coating application to form thin film becomes possible, but the amount of volatile organic compounds (VOCs) generated per application area increases, leading to an increase in environmental load
Solution Approach 1:
The invention changes the formulation parameters by using siloxane binder with high SiO2 content (70-90 mass%) and controlling nonvolatile content to 60-80 mass%, enabling thin film formation without excessive solvent dilution, thus reducing VOC emissions
Solution Approach 2:
The siloxane binder system creates a more environmentally friendly coating environment by reducing reliance on organic solvents, thereby decreasing VOC emissions and environmental impact
3Productivity
If the thickness of the anti-rust coating is made smaller to enhance welding speed and improve productivity, then productivity is improved, but anticorrosive properties become insufficient
Solution Approach 1:
The invention optimizes the Zn/SiO2 mass ratio to 10-50 and controls zinc powder particle size to 3-15 μm, enabling thin coating films to provide sufficient anticorrosive protection while maintaining high welding speed and productivity
Solution Approach 2:
The composite coating system with controlled zinc powder and siloxane binder ratio provides enhanced anticorrosive properties even at reduced thickness, allowing thin film formation without sacrificing corrosion protection
4Ease of manufacture
If existing primary anti-rust coating is applied with existing applicator to form thin film, then conventional equipment can be used, but it is difficult to form a thin film with average dry film thickness of 10 μm or less
Solution Approach 1:
The invention modifies the coating parameters including viscosity control through siloxane binder selection and particle size distribution of zinc powder (3-15 μm), enabling compatibility with existing applicators while achieving thin film formation at 10 μm or less
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 composition achieves a dry film thickness of 10 µm or less with improved weldability and anticorrosive properties, reducing environmental impact and preventing weld defects.
Implementation Method 1
an alkyl silicate condensate (A) having a weight average molecular weight (Mw) of 1,500 to 8,000
Implementation Method 2
an alkyl silicate condensate (A) having a weight average molecular weight (Mw) of 1,500 to 8,000
Data Source
Figure 1
AI summary
The present invention provides an anti-rust coating composition comprising an alkyl silicate condensate (A) having a weight average molecular weight of 1,500 to 8,000, zinc powder (B), and one or more pigments (C) selected from the group consisting of an extender pigment, an anti-rust pigment and a color pigment, wherein the mass ratio of the zinc powder (B) to the pigment (C) ((B)/(C)) is 2.0 to 5.0, and the pigment volume concentration (PVC) is 60 to 70%. The anti-rust coating composition of the present invention has a long pot life, and can form an anti-rust coating film having an average dry film thickness of 10 µm or less by use of a conventional applicator and can also form an anti-rust coating film having excellent anticorrosive properties even as such a thin film and having excellent weldability to a steel material.