Epoxy Anti-Corrosion Coating Bubble Suppression
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Solution Overview
Problem
Epoxy-based anticorrosive coating compositions face challenges with bubble entrapping when applied using a brush or roller, particularly at welding lines and edges, where film thickness is difficult to ensure, and conventional defoaming agents like silicone-based and acrylic/vinyl ether-based agents often compromise adhesion and effectiveness.
Innovation Solution
Incorporating a poly-α-olefin with structural units derived from α-olefins having 6 or more carbon atoms into the epoxy-based anticorrosive coating composition, along with a silane coupling agent, amide wax, and a liquid acrylic polymer, to enhance defoaming, adhesion, and anticorrosive properties, while minimizing bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a brush or roller is used for stripe coating at welding lines and edges, then film thickness can be ensured, but bubbles remain on the coating film surface impairing appearance
Solution Approach 1:
The patent introduces a specific defoaming agent as an intermediary substance to eliminate bubbles caused by brush or roller application. The defoaming agent acts as a mediator between the coating material and the application method, allowing manual stripe coating to proceed while suppressing bubble formation on the surface.
Solution Approach 2:
The patent modifies the chemical composition parameters of the coating material by adding a defoaming agent in specific amounts (0.01-5 parts by weight based on epoxy resin). This parameter change enables the coating to maintain its adhesion and anticorrosive properties while reducing surface tension to prevent bubble entrapment during manual application.
2Object-affected harmful factors
If conventional defoaming agents (silicone-based or acrylic/vinyl ether-based) are added to the coating material, then bubble formation is reduced, but adhesion to metal substrates deteriorates
Solution Approach 1:
The patent employs a specific type of defoaming agent that acts temporarily during the coating process to eliminate bubbles, then disappears or becomes integrated into the coating matrix without long-term negative effects. The defoaming agent performs its function during application and drying, then ceases to interfere with the coating's adhesion properties.
Solution Approach 2:
The patent creates a composite coating system that combines epoxy resin, curing agent, and defoaming agent in specific proportions. This composite formulation achieves synergistic effects where the defoaming agent provides bubble suppression while the epoxy-curing agent system maintains strong adhesion to metal substrates, overcoming the limitations of conventional defoaming agents.
3Area of stationary object
If stripe coating is performed at welding lines and edges, then complete coverage is achieved, but application complexity increases
Solution Approach 1:
The patent divides the coating application process into two segments: spray coating for general areas and manual stripe coating for welding lines and edges. This segmentation allows each method to be used where it is most effective, with the defoaming agent specifically addressing the bubble issue in the manual stripe coating segment.
Solution Approach 2:
The defoaming agent serves as an intermediary that enables manual stripe coating to be performed more easily by eliminating the bubble problem. This intermediary substance reduces the skill requirement and simplifies the application process for achieving complete coverage at welding lines and edges.
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 excellent adhesion and anticorrosive performance with reduced bubble formation on the coating film surface, even when applied with a brush or roller, making it suitable for complex structures like ballast tanks.
Implementation Method 1
Incorporating a poly-α-olefin with structural units derived from α-olefins having 6 or more carbon atoms into the epoxy-based anticorrosive coating composition, along with a silane coupling agent, amide wax, and a liquid acrylic polymer, to enhance defoaming, adhesion, and anticorrosive properties, while minimizing bubble formation.
Implementation Method 2
Incorporating a poly-α-olefin with structural units derived from α-olefins having 6 or more carbon atoms into the epoxy-based anticorrosive coating composition, along with a silane coupling agent, amide wax, and a liquid acrylic polymer, to enhance defoaming, adhesion, and anticorrosive properties
Implementation Method 3
An anticorrosive coating composition is applied on a surface of a steel plate or the like to form an anticorrosive coating film having a thickness of several hundred to several thousand micrometers. This allows the surface of the steel plate or the like to be covered with the anticorrosive coating film to prevent the steel plate or the like from contacting with oxygen, salt, vapor, and the like, thereby preventing the corrosion of the steel plate or the like.
Data Source
Figure 1
AI summary
An anticorrosive coating composition is provided which is excellent in adhesion to a substrate and in anticorrosiveness, and which provides a coating film whose surfaces hardly have bubbles remaining thereon even when the coating composition is applied by using a brush or a roller. The anticorrosive coating composition includes an epoxy resin (a), a curing agent (b) and a poly-α-olefin (c) that includes a structural unit derived from an α-olefin having 6 or more carbon atoms.