Anti-corrosion Coating Composition Resolving Spray Dust Adhesion
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Solution Overview
Problem
Conventional anticorrosive coating compositions used for forming thick films on metal substrates, such as ship structures, face issues with adhesion reduction due to spray dust attachment, particularly in environments where solvent vapor leads to premature drying, and struggle to achieve film thicknesses of 100 µm or more without sagging.
Innovation Solution
An anticorrosive coating composition comprising an epoxy resin, a curing agent, a silane coupling agent, oxidized polyethylene wax, and an extender pigment, with minimal fatty acid amide wax, which provides excellent adhesion and prevents sagging, even when spray dust attaches to the surface during application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an epoxy-based anticorrosive coating composition including amide wax-based thixotropic agent is used to form thick film, then adhesion to substrate and anticorrosive properties are improved, but spray dust attachment reduces adhesion and film integrity is compromised
Solution Approach 1:
The patent removes the amide wax-based thixotropic agent from the coating composition to eliminate the source of spray dust that causes adhesion problems. This extraction of the problematic component resolves the contradiction by preventing spray dust attachment while maintaining film thickness capability through alternative formulation
Solution Approach 2:
The patent changes the chemical composition parameters by replacing amide wax with alternative thixotropic agents or formulation approaches that do not generate spray dust. This parameter change maintains the desired adhesion and anticorrosive properties while eliminating the harmful spray dust effect
2Length of stationary object
If coating composition is applied to form thick film of 100 µm or more, then anticorrosive protection is improved, but sagging occurs during application
Solution Approach 1:
The patent adjusts the viscosity and rheological parameters of the coating composition by removing amide wax and using alternative formulations. This enables the composition to maintain structural stability at high film thicknesses without sagging, while still achieving the required 100 µm or more thickness for adequate corrosion protection
Solution Approach 2:
The patent employs a composite coating formulation that combines epoxy resin with alternative thixotropic agents and extender pigments. This composite approach provides the necessary body and sag resistance to maintain film integrity at thick applications while achieving the required corrosion protection thickness
3Productivity
If solvent vapor environment causes premature drying, then coating efficiency is improved, but adhesion is reduced due to spray dust attachment
Solution Approach 1:
The patent eliminates the amide wax component that generates spray dust, thereby removing the source of adhesion problems that occur in solvent vapor environments. This allows efficient coating application in challenging environments without the penalty of reduced adhesion from spray dust attachment
Solution Approach 2:
The patent transforms the challenging solvent vapor environment into a beneficial condition by removing the vulnerable amide wax component. The premature drying that would normally cause spray dust adhesion problems no longer affects performance, allowing efficient coating application even in high-temperature, high-humidity conditions
Data Source
Figure 1
AI summary
The present invention relates to an anticorrosive coating composition for use in the formation of a coating film having a dry film thickness of 100 µm or more comprising an epoxy resin (A), a curing agent (B), a silane coupling agent (C), an oxidized polyethylene wax (D), and an extender pigment (E), but substantially includes no fatty acid amide wax. 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.