Composite Coating System for Substrate Corrosion and Outgassing Protection
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Solution Overview
Problem
Current material protection systems are inadequate for providing long-lasting anticorrosion, barrier, and antioxidant properties, especially in harsh environments such as marine and space applications, where they fail to prevent corrosion, erosion, and outgassing, and are often brittle and prone to mechanical damage.
Innovation Solution
A coating system comprising a combination of pyrolytic graphite or boron nitride-based layer A and a polymeric matrix with 2D flakes in layer B, which provides superior anticorrosion, barrier, and antioxidant properties, along with high mechanical strength, thermal conductivity, and self-healing capabilities, suitable for both metallic and polymeric substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional protective coatings (metallic, inorganic, organic) are applied to protect metals in chlorine-rich environments, then corrosion protection is provided, but the coatings fail to provide long-lasting protection due to rapid conversion of zinc to soluble zinc chloride and wash-away effects
Solution Approach 1:
The patent employs a composite coating system comprising multiple layers with distinct functions: a polymeric matrix layer providing flexibility and adhesion, an inorganic barrier layer (such as sol-gel derived silica or alumina) providing chemical resistance, and optionally a metallic layer for sacrificial protection. This multi-material composite structure synergistically combines the advantages of each material while mitigating their individual weaknesses in chlorine-rich environments.
Solution Approach 2:
The protective coating is divided into multiple functional layers rather than using a single homogeneous coating. Each layer is optimized for specific purposes: the polymeric layer provides mechanical flexibility and substrate adhesion, the inorganic layer provides chemical inertness and barrier properties, and the layered structure creates tortuous paths for corrosive species, enhancing overall protection duration.
2Reliability
If barrier coatings (dense and cohesive polymeric and inorganic coatings) are used to prevent release of inhibitors, then uniform material protection is improved, but the release of inhibitors is hindered thus reducing their effective utilization
Solution Approach 1:
The patent introduces a controlled-release mechanism where the inorganic barrier layer acts as an intermediary between the polymeric matrix and the external environment. This intermediary layer allows selective permeation and controlled release of inhibitive species while maintaining barrier protection, preventing the buildup of pressure that would cause blistering while ensuring uniform protection across the coating surface.
Solution Approach 2:
The inorganic barrier layer is designed with a controlled porous or nanoscale structure that provides tortuous diffusion paths for corrosive species while allowing controlled release of inhibitors. The porous structure at the nanoscale level maintains barrier integrity while enabling gradual release of protective agents, preventing blistering effects.
3Reliability
If inorganic coatings (such as silica films) are used to provide barrier protection, then impermeability towards corrosive species is improved, but the coatings become inherently brittle requiring blending with organic coating materials
Solution Approach 1:
The patent creates a composite coating system where inorganic barrier layers (sol-gel derived silica, alumina, or other metal oxides) are combined with a polymeric matrix. The inorganic phase provides impermeability and chemical resistance, while the polymeric matrix provides mechanical flexibility and toughness. The interfacial bonding between the two phases creates a synergistic effect where the composite coating exhibits both barrier properties and mechanical integrity.
Solution Approach 2:
The coating system exhibits local quality differentiation where the inorganic barrier layer provides localized impermeability and chemical resistance at the molecular level, while the polymeric matrix provides localized mechanical flexibility and adhesion. This spatial differentiation of functions allows the coating to simultaneously achieve high barrier performance and mechanical strength without requiring homogeneous composition throughout.
4Ease of manufacture
If organic coatings (solvent- or water-borne resins) are used for large-area applications, then ease of application is improved, but the coatings show insufficient impact resistance, creation of cracks or micro-pores, and permeability to corrosive agents
Solution Approach 1:
The patent combines organic polymeric resins with inorganic barrier materials in a composite coating system. The organic component maintains ease of application through conventional spray or dip coating methods, while the inorganic component (such as sol-gel derived networks or suspended ceramic particles) provides enhanced impact resistance, crack resistance, and impermeability to corrosive agents. The composite structure creates a more robust coating that retains application advantages while overcoming the weaknesses of pure organic coatings.
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 coating system significantly reduces corrosion rates, gas and water permeability, and outgassing, while maintaining mechanical integrity and thermal stability, offering superior protection in extreme conditions compared to traditional coatings.
Implementation Method 1
The coating system comprises at least one layer A and at least one layer B... layer A and layer B synergistically determine the mechanical, thermal, chemical, electrical and ion/gas barrier properties of the coating system
Implementation Method 2
layer A and layer B synergistically determine the mechanical, thermal, chemical, electrical and ion/gas barrier properties of the coating system
Implementation Method 3
Coating system for protecting a substrate... with superior and long-lasting anticorrosion, barrier, antierosion and antioxidant properties
Implementation Method 4
that allows a reduction of polymer outgassing effects
Data Source
AI summary
The present invention relates to a coating system for protecting a substrate comprising at least one layer A and at least one layer B, wherein said layer A is made of a material selected from the group consisting of pyrolytic graphite, pyrolytic boron nitride, compressed expanded graphite, hot-pressed turbostratic boron nitride, compressed graphene flakes, compressed hexagonal boron nitride flakes, graphitized graphene oxide flakes or a combination thereof; and said layer B is made of a composite comprising a polymeric matrix and 2D flakes, said 2D flakes being made of a material selected from the group consisting of graphene, graphene oxides, reduced graphene oxide, heteroatom-doped graphene, hexagonal boron nitride, metal chalcogenides, metal oxides, metal chalcogenide halides, metal halides, phosphotrichalcogenides, MXenes, metal carbides, metal nitrides, layered hydroxides, alkaline-earth metal silicides, alkaline-earth metal bromides, alkaline-earth metal germanides and alkaline-earth metal stannides, layered peroskivtes, phosphorene, silicene, antimonene, germanene, boronene, stanene, bismuthene and combination thereof. It further relates to a coated substrate comprising a substrate and the coating system.