Galvanized Basin Liner Coating for Corrosion and Leak Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing liquid holding structures, such as cooling towers and evaporative condensers, face challenges with corrosion due to exposure to corrosive environments and mechanical stresses, leading to leaks and structural integrity issues, particularly with galvanized and stainless steel structures, and existing liners fail to adhere well to substrates and are prone to chemical reactions with sealants.
Innovation Solution
A factory-installed liner system using galvanized steel with an electrostatically applied powdered polymer coating, followed by a polyurethane or polyurea barrier coating, which provides a strong bond and corrosion resistance, eliminating the need for separate sealants and reducing the number of fasteners required, while incorporating link holes for enhanced drainage and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer coating is applied to protect the metal substrate from corrosion, then corrosion resistance is improved, but the coating is susceptible to blistering, cracking, and peeling when exposed to chemicals and water continuously
Solution Approach 1:
The coating system is divided into multiple layers: an epoxy primer layer applied directly to the metal substrate for strong adhesion and corrosion protection, followed by a polyurethane topcoat layer for chemical resistance and durability. This segmented approach allows each layer to specialize in protecting against different failure modes, preventing the single-layer coating from blistering, cracking, and peeling under continuous chemical and water exposure.
Solution Approach 2:
The invention uses a composite coating system combining epoxy and polyurethane materials. The epoxy primer provides excellent adhesion to metal and corrosion protection, while the polyurethane topcoat offers superior chemical resistance and flexibility. This composite structure leverages the strengths of each material to create a coating system that resists blistering, cracking, and peeling under continuous exposure to chemicals and water, thereby improving both corrosion resistance and long-term durability.
2Strength
If galvanized steel structures are used to hold liquid, then structural strength is improved, but the galvanized coating breaks down under prolonged exposure to treated water with high chlorides, exposing the panels to corrosion
Solution Approach 1:
The invention applies an epoxy primer coating to the galvanized steel substrate before exposing it to the corrosive liquid environment. This preliminary protective layer prevents direct contact between the corrosive treated water with high chlorides and the galvanized coating, stopping the breakdown process before it can compromise the structural integrity. The primer acts as a first line of defense, preserving both the galvanized coating and the underlying steel structure.
Solution Approach 2:
The dual-layer coating system combines epoxy primer with polyurethane topcoat to protect galvanized steel structures. The epoxy primer adheres strongly to the galvanized surface and provides a barrier against corrosive chemicals, preventing the galvanized coating from breaking down. The polyurethane topcoat adds an additional layer of chemical resistance. This composite protection allows the galvanized steel to maintain its structural strength while being protected from corrosion by treated water with high chlorides.
3Reliability
If polyurethane liners are applied to basins, then corrosion protection is improved, but the liners flow through cracks and seams in liquid state causing uneven coating, especially where needed most at the seams
Solution Approach 1:
The invention applies the polyurethane coating while the basin structure is still warm from manufacturing, and immediately after applying the epoxy primer. The warmth of the substrate helps prevent the polyurethane from flowing excessively, and the fresh epoxy primer provides a tacky surface that holds the polyurethane in place. This timing allows the coating to be applied evenly across the entire surface, including seams and corners, before the material has a chance to flow and create unevenness.
Solution Approach 2:
The invention exploits the temperature parameter by applying the polyurethane coating when the basin substrate is still warm from manufacturing. The elevated temperature reduces the viscosity and flow tendency of the polyurethane material, allowing it to be applied more uniformly. Additionally, the invention changes the temporal parameter by applying the coating immediately after the epoxy primer while it is still tacky, creating a bonded surface that prevents polyurethane flow and ensures even coating distribution across seams and other critical areas.
4Strength
If multiple fasteners are used to attach panels together, then structural assembly is improved, but the fasteners and seams become vulnerable points for corrosion and leaks
Solution Approach 1:
The invention merges the structural fastening function with the sealing function by having the epoxy primer and polyurethane coating system continuously cover and seal over the fasteners and seams. Instead of treating fasteners as separate components that need separate sealing, the coating system is applied over the entire assembled structure, integrating the fasteners into the protected surface. This eliminates vulnerable points by making the fasteners and seams part of the continuous corrosion and leak protection barrier.
Solution Approach 2:
The epoxy primer and polyurethane coating system act as an intermediary layer between the fasteners/seams and the corrosive liquid environment. This intermediate protective barrier prevents direct contact between the corrosive treated water and the fasteners or seam areas, eliminating them as vulnerable points for corrosion and leaks. The coating system mediates the interaction between the structural assembly and the corrosive environment, protecting the assembly while maintaining its structural integrity.
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 effectively prevents corrosion and leaks by providing a robust, chemically bonded barrier coating that resists corrosive conditions, reduces the need for additional sealants, and enhances structural integrity by ensuring better adhesion and durability.
Implementation Method 1
an organic powder coating electrostatically applied to both sides of the steel panels and to the inner surfaces of the holes
Implementation Method 2
baked to cure resulting in a sealing coat having good adhesion
Implementation Method 3
The barrier coating is applied in liquid form over the seams and any portion of the fasteners exposed to the inside of the vessel
Data Source
AI summary
A liner and method of application for use on a metal surface to protect metal structures such as cooling towers, evaporative condensers, and other liquid containing vessels such as tanks from corrosion, leaks, and wear. The liner is an inexpensive apparatus and process comprising a coated metal having a second sealing and bonding layer and a third protective sealing layer. The liner method comprises applying an organic bonding layer onto the galvanized substrate, and applying an elastomeric barrier coating to the bonding layer. The barrier coating material is applied to preseal the seams between adjoining panels assembled to form the basin. The barrier coating is applied to the entire inside of the basin to form a homogenous barrier coating extending out of the basin. The liner edge is isolated from the basin by extending the liner to a point between the basin and an upper section. The liner comprises galvanizing layer, a bonding layer on the galvanized metal, and an elastomeric third layer on the bonding layer. The liner further comprises preseals at the seams, corner molds and link holes in the substrate to attach and protect the liners integrity.