Aqueous Silane Coating for Chromium-Free Metal Corrosion Protection
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Solution Overview
Problem
Current corrosion protection systems for metals, particularly galvanized steel, often rely on toxic heavy metal ions like Cr(VI) and Co(II), which are environmentally harmful and require stable, environmentally friendly alternatives that provide durable corrosion protection without the use of these toxic substances.
Innovation Solution
An aqueous, storage-stable silane-based composition enhanced with specific metal salts such as nitrates or acetates of chromium(III), aluminum(III), zinc(II), and cerium(III) is used, offering excellent bare corrosion protection and compatibility with common coating systems, while being free from volatile organic compounds (VOCs) and toxic heavy metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If toxic heavy metal ions like Cr(VI) and Co(II) are used in corrosion protection systems, then durable corrosion protection is achieved, but environmental harm increases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing toxic Cr(VI) and Co(II) ions with non-toxic metal salts (Al³⁺, Zn²⁺, vanadium, cerium) in the aqueous silane system, maintaining corrosion protection functionality while eliminating environmental harm
Solution Approach 2:
The patent converts the potentially harmful effect of metal ion toxicity into a beneficial outcome by using alternative metal salts that provide comparable or superior corrosion protection without the environmental hazards, turning a harmful approach into a beneficial one
2Object-generated harmful factors
If aqueous silane-based compositions are used to replace toxic ions, then environmental friendliness improves, but corrosion protection durability may be compromised
Solution Approach 1:
The patent creates a composite aqueous system combining silane-based compounds with non-toxic metal salts (Al³⁺, Zn²⁺, vanadium, cerium) to achieve both environmental friendliness and durable corrosion protection simultaneously
Solution Approach 2:
The patent modifies the chemical parameters of the corrosion protection system by incorporating specific non-toxic metal salts at optimized concentrations, ensuring that the aqueous silane composition achieves both low VOC content and superior corrosion resistance
3Object-affected harmful factors
If galvanized surfaces are treated with mineral oil or passivated directly after galvanization, then white rust formation is prevented, but painting quality and surface preparation are compromised
Solution Approach 1:
The patent applies a preliminary treatment with aqueous silane composition containing non-toxic metal salts to the galvanized surface before painting, which prevents white rust formation while creating an optimized surface that enhances subsequent coating adhesion and quality
Solution Approach 2:
The patent introduces an intermediary aqueous silane-based treatment layer between the galvanized surface and the final coating, which serves as a bridge that prevents white rust while providing excellent adhesion for subsequent painting operations
4Stability of the object's composition
If storage-stable aqueous compositions are developed, then environmental friendliness and stability improve, but corrosion protection effectiveness must be maintained
Solution Approach 1:
The patent optimizes the chemical parameters of the aqueous silane system by selecting specific non-toxic metal salts and their concentrations, ensuring the composition remains stable during storage while maintaining effective corrosion protection when applied
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 provides durable corrosion resistance to metal surfaces, including galvanized steel, with excellent storage stability and adherence to further coatings, reducing white rust formation and environmental impact.
Implementation Method 1
aqueous, silane-based composition... incorporating metal salts such as nitrates or acetates of chromium(III), aluminum(III), zinc(II), vanadium(II), and cerium(III)
Implementation Method 2
silane-based composition... provides durable corrosion resistance to metals
Implementation Method 3
The quality of the adhesive bonding depends inter alia on the metal alloy, since the composition of the metal surface determines the Si—O-metal bond
Data Source
AI summary
The present invention relates to a furnace (12) for melting heated glass using burners (13), wherein the combustion energy is at least partially produced by oxy-fuel combustion, and wherein at least a portion of the oxygen used in the burners (13) is produced by separation, on a ceramic separation membrane (18), from a gaseous mixture including oxygen, the oxygen from the separation being directly channeled into at least one burner (13).