Epoxy Coating Film Chemical Resistance via Solvent Retention
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Solution Overview
Problem
Existing anticorrosion paints face challenges with safety and health concerns due to tar content, limited compatibility of epoxy resin and amine-type curing agents, and insufficient performance for high-level anticorrosion and waterproofing applications, particularly with Mannich-type curing agents leaving phenol residues.
Innovation Solution
A coating film formed by curing an epoxy resin composition containing specific ratios of solvents, metaxylylenediamine, unsaturated carboxylic acids, and monocarboxylic acids, which includes a solvent content of 1% to 20% by mass, enhancing chemical resistance and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tar epoxy paint is used for anticorrosion, then chemical resistance and waterproofness are excellent, but safety and health problems arise due to tar content
Solution Approach 1:
The patent extracts and removes the harmful tar component from the epoxy paint system while retaining the beneficial chemical resistance properties. This is achieved by formulating a tar-free epoxy resin composition that maintains protective performance without the health and safety hazards associated with tar-containing paints.
Solution Approach 2:
The patent employs a composite resin system combining epoxy resin with specific curing agents (amine-type or Mannich-type) to create a multi-component formulation that achieves both chemical resistance and safety requirements. The composite nature of the curing agents provides synergistic effects that maintain protective properties while eliminating harmful tar content.
2Object-affected harmful factors
If non-tar paint using petroleum resin is used, then safety concerns are reduced, but compatibility between epoxy resin, amine-type curing agent and petroleum resin is problematic
Solution Approach 1:
The patent modifies the chemical parameters of the resin composition by carefully selecting and proportioning epoxy resin, curing agent, and petroleum resin components. By controlling the ratios and chemical characteristics of these components, the formulation achieves compatibility among all constituents while maintaining safety and performance properties.
3Reliability
If Mannich-type curing agent is used for high-level anticorrosion performance, then waterproofness improves, but phenol residues create safety and health concerns
Solution Approach 1:
The patent removes or minimizes phenol residues from the Mannich-type curing agent formulation while preserving the waterproofing capabilities. This is achieved through careful control of the Mannich condensation reaction conditions and selection of starting materials that produce fewer phenolic byproducts.
Solution Approach 2:
The patent applies different qualities to different components of the curing system, using amine-type curing agents in certain applications and modified Mannich-type agents in others, depending on the specific balance between waterproofness requirements and phenol residue concerns.
4Reliability
If tar epoxy paint is used, then anticorrosion performance is excellent, but maintenance is difficult and appearance is poor
Solution Approach 1:
The patent transitions from the traditional black color of tar epoxy paints to lighter, more aesthetically pleasing colors achieved through tar-free formulations. This color change not only improves appearance but also facilitates inspection and maintenance activities.
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 film achieves both good appearance and high chemical resistance, making it suitable for various applications such as ship coatings, heavy-duty coatings, and tank coatings while minimizing health risks and improving compatibility.
Implementation Method 1
a coating film formed by curing of an epoxy resin composition containing at least an epoxy resin, an epoxy resin curing agent and a solvent
Implementation Method 2
the coating film contains the solvent in a ratio of 1% by mass or more and 20% by mass or less
Data Source
AI summary
A coating film formed by curing of an epoxy resin composition containing at least an epoxy resin, an epoxy resin curing agent and a solvent, wherein the coating film contains the solvent in a ratio of 1% by mass or more and 20% by mass or less, and the epoxy resin curing agent is a reaction product of the following (A) and (B). (A) At least one selected from the group consisting of metaxylylenediamine and paraxylylenediamine. (B) At least one selected from the group consisting of an unsaturated carboxylic acid represented by the following formula (1) and a derivative thereof:wherein R1 and R2 each independently represent a hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an aralkyl group having 1 to 8 carbon atoms, or an aryl group.