Multicomponent Corrosion Inhibitor Mix for Galvanic Protection
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Solution Overview
Problem
Existing corrosion inhibitors in film-forming binders often require extensive experimentation to determine effectiveness and may inadvertently promote corrosion, especially in environments like those around vehicles, where galvanic corrosion is a concern.
Innovation Solution
A multi-component corrosion inhibitor comprising at least three metallic salt components, including lithium-free phosphate salts like nickel phosphate or magnesium phosphate, and optionally non-phosphate lithium salts, is used in conjunction with film-forming binders to inhibit corrosion effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-component corrosion inhibitors are used in film-forming binders, then the formulation is simple, but the corrosion inhibition effectiveness is insufficient and may inadvertently promote corrosion
Solution Approach 1:
The patent combines multiple corrosion inhibitor components (at least three different inhibitors from different chemical classes) into a single multi-component corrosion inhibitor mix. This merging of different inhibitor mechanisms synergistically improves corrosion protection effectiveness while preventing the promotion of corrosion that occurs with single-component inhibitors.
Solution Approach 2:
The invention creates a composite corrosion inhibitor system by formulating at least three different inhibitor compounds together in specific proportions. This composite approach leverages the complementary mechanisms of different inhibitor types (e.g., anodic, cathodic, and film-forming inhibitors) to achieve superior and more reliable corrosion protection.
2Reliability
If extensive experimentation is conducted to determine inhibitor effectiveness, then corrosion protection can be optimized, but time and resources are significantly consumed
Solution Approach 1:
The patent performs preliminary formulation work by pre-determining effective combinations of at least three inhibitor components in specific proportions. This preliminary action establishes a proven multi-component formula that can be directly applied to film-forming binder formulations, eliminating the need for extensive subsequent experimentation to determine effectiveness.
3Reliability
If lithium-containing inhibitors are used, then corrosion inhibition may be effective, but environmental and safety concerns arise
Solution Approach 1:
The invention extracts and removes lithium-containing compounds from the corrosion inhibitor formulation. The multi-component inhibitor mix achieves effective corrosion protection using alternative, lithium-free inhibitor components, thereby eliminating the environmental and safety hazards associated with lithium while maintaining corrosion inhibition effectiveness.
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 multi-component corrosion inhibitor significantly reduces corrosion on metal substrates, particularly in harsh environments, by forming a protective film that prevents galvanic corrosion, as demonstrated by initial open cell potential and potentiodynamic polarization tests.
Implementation Method 1
forming a protective film that prevents galvanic corrosion
Implementation Method 2
react with the surface of the metal to inhibit corrosion including galvanic corrosion
Data Source
AI summary
Corrosion inhibitor mixes comprising multiple salts. One mix includes zinc citrate, zinc oxalate and magnesium phosphate. A second mix includes the same two zinc salts, nickel oxalate and nickel phosphate. Either mix may be added to a film-forming binder such as a polymer suitable for a paint or primer, to inhibit corrosion, especially when used with a metallic substrate. The resulting product of the inhibitor mix and binder is especially useful in inhibiting corrosion when applied to an aircraft surface.