Molten Polymer Coating for Subsea Corrosion Protection
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Solution Overview
Problem
Current corrosion protection methods for subsea metal structures are inadequate, as they are often labor-intensive, environmentally harmful, and fail to provide long-term protection against high pressures and cold temperatures, with existing coatings being porous, non-reusable, and not suitable for complex structural shapes.
Innovation Solution
A coating composition comprising cellulose acetate, a plasticizer, a corrosion inhibitor, and a vegetable oil, mixed with a stabilizer, which can be easily applied, dries rapidly, and remains flexible and non-porous, allowing for easy removal and reapplication, while providing long-term protection against corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coatings are applied to protect metal structures, then corrosion protection is provided, but the coatings become porous and degrade after six months
Solution Approach 1:
The invention changes the physical and chemical parameters of the coating by using a molten polymer composition that is applied in a liquid state and then allowed to solidify. This phase change process creates a non-porous, dense coating structure that maintains its protective properties over time, resolving the contradiction between providing corrosion protection and maintaining long-term durability.
Solution Approach 2:
The invention uses a composite material system consisting of polymer resins, plasticizers, and stabilizers that work together to create a coating with both immediate protective properties and long-term durability. The specific combination of materials creates a coating that is both non-porous and flexible, maintaining its integrity for extended periods in corrosive environments.
2Area of stationary object
If protective coatings are applied to complex structural shapes with crevices, then surface coverage is improved, but moisture pools in crevices and causes corrosion
Solution Approach 1:
The invention uses a flexible polymer-based coating that can conform to complex structural shapes and penetrate into crevices. The flexibility of the molten polymer allows it to flow into and coat difficult-to-reach areas, creating a continuous protective film that seals crevices and prevents moisture accumulation, thus maintaining corrosion resistance while achieving complete surface coverage.
3Reliability
If conventional coatings are applied and cured, then corrosion protection is achieved, but the process requires over eight hours and creates waste
Solution Approach 1:
The invention exploits the phase transition of the polymer composition from liquid (molten) state to solid state. The coating is applied in a molten liquid state that allows for easy application and rapid spreading, then it solidifies quickly upon cooling or contact with the substrate. This phase change mechanism eliminates the need for lengthy curing processes, reducing application time from over eight hours to a much shorter duration while maintaining effective corrosion protection.
4Reliability
If protective coatings are removed and reapplied, then updated protection is provided, but the removal process damages the underlying metal surface
Solution Approach 1:
The invention creates a coating that is designed to be removable and replaceable without damaging the underlying substrate. The polymer-based coating can be easily removed when needed and reapplied to provide updated corrosion protection. The coating acts as a disposable protective layer that can be replaced without compromising the integrity of the metal surface beneath, allowing for maintenance and updates to the protective system.
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 composition effectively protects subsea structures from corrosion, remains flexible under high pressures and cold temperatures, is ecologically safe, and can be reused, offering a reliable and sustainable solution for complex structures with minimal waste and quick application, maintaining integrity for over thirty years.
Implementation Method 1
The coating composition effectively protects subsea structures from corrosion
Implementation Method 2
dries rapidly
Data Source
AI summary
A coating composition for application to a component or structure has cellulose acetate, a plasticizer with an antioxidant, a corrosion inhibitor with an antioxidant, a vegetable oil, and a stabilizer. The plasticizer is linseed oil. The corrosion inhibitor is canola oil. The vegetable oil is epoxidized soybean oil. The stabilizer is titanium dioxide. These components are intimately mixed together so as to form a solid mixture. The solid mixture is converted into a solid state and applied to the component or structure. The liquid state is then dried on the component or structure for a period of time.