Anticorrosive Coating Composition with Liquid Acrylic Polymer
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Solution Overview
Problem
Conventional anticorrosive coating compositions used in ship structures, such as ballast tanks, face issues with adhesion reduction due to spray dust attachment during application, particularly in environments where solvent vapor leads to premature drying, causing reduced film adhesion and anticorrosive performance.
Innovation Solution
Incorporating a liquid acrylic polymer with a structural unit derived from an acrylate having an alkyl group of 4 to 18 carbon atoms into the anticorrosive coating composition, which includes an epoxy resin and an amide wax, to enhance adhesion and prevent spray dust from reducing the film's adhesion to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spray coating is used to apply anticorrosive coating composition on ship structures, then coating efficiency and coverage are improved, but spray dust attaches to surfaces and reduces adhesion of subsequent coating layers
Solution Approach 1:
The patent introduces a specific polymer component as an intermediary substance in the coating composition that modifies the interaction between spray dust and the coating film. This polymer acts as a mediator that prevents the harmful effect of spray dust attachment, allowing spray coating to be used without compromising adhesion. The composition includes specific resins and additives that create a surface property preventing spray dust from interfering with subsequent coating layers.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the coating composition to control spray dust behavior. By adjusting composition parameters such as resin type, solvent content, and additive selection, the coating maintains optimal viscosity and surface properties that prevent spray dust attachment from reducing adhesion, while still enabling efficient spray application.
2Reliability
If double coating is applied to ensure sufficient film thickness and anticorrosive properties, then corrosion protection is improved, but adhesion between first and second coating layers is reduced due to spray dust attachment
Solution Approach 1:
The coating composition contains specific polymer components that act as intermediaries between the first and second coating layers. These components prevent spray dust from creating adhesion barriers, ensuring strong inter-layer bonding while maintaining the required film thickness through double coating application.
Solution Approach 2:
The first coating layer is formulated with specific adhesion-promoting components that prepare the surface for subsequent coating application. This preliminary action ensures that even if spray dust attaches during the interval between coatings, the adhesion remains sufficient for strong inter-layer bonding.
3Shape
If amide wax-based thixotropic agent is used to form thick coating films, then anti-sagging and anti-settling properties are improved, but adhesion to substrate and subsequent layers is reduced when spray dust attaches
Solution Approach 1:
The patent uses a composite coating composition that combines amide wax-based thixotropic agents with specific polymer components and additives. This composite formulation maintains the anti-sagging and anti-settling properties necessary for thick film formation while the other components compensate for potential adhesion reduction caused by spray dust attachment.
Solution Approach 2:
The patent optimizes the concentration and interaction parameters of the thixotropic agent with other coating components to maintain proper rheology for thick film application while preventing adhesion loss. By carefully controlling these parameters, the coating achieves both good sag resistance and maintained adhesion despite spray dust exposure.
Data Source
Figure 1
AI summary
The present invention relates to an anticorrosive coating composition comprising an epoxy resin (a), a curing agent (b), an amide wax (c), and a liquid acrylic polymer (d) including a structural unit derived from an acrylate having an alkyl group of 4 to 18 carbon atoms. The anticorrosive coating composition of the present invention can form an anticorrosive coating film that is excellent adhesion to a metal substrate, anticorrosive properties and so on.