One-Part Polymerizable Coating for Corrosion Resistance
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Solution Overview
Problem
Current polymerizable coatings for protecting steel surfaces from corrosion are hindered by the need for two-part formulations, which complicate application, lead to wasted material, and are ineffective against salt corrosion, especially in marine environments, and have limitations in adhesion and viscosity issues.
Innovation Solution
A one-part, storage-stable polymerizable formulation using monomeric or oligomeric ethylenically unsaturated compounds, dicyclopentadiene modified oligomers, and an organic solvent that accelerates polymerization upon solvent evaporation, allowing for spray or brush application and forming a high-crosslink-density coating with excellent anti-corrosion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-part polymerizable formulation is used to initiate polymerization reaction, then coating formation is achieved, but the formulation must be applied on a timetable consistent with cure rate and viscosity increases, and any unused formulation is wasted
Solution Approach 1:
The patent combines the polymerizable compound and curing agent into a single one-part formulation that remains stable during storage and application. The formulation automatically initiates polymerization upon solvent evaporation, eliminating the need for separate mixing of two parts and removing time constraints on application.
Solution Approach 2:
The formulation is prepared in advance with all components pre-combined and stabilized. The polymerization reaction is designed to automatically commence after solvent evaporation without requiring additional mixing or activation steps, allowing the coating to be applied at any time within a reasonable window.
2Reliability
If a two-part polymerizable formulation is used, then polymerization reaction is initiated, but the formulation viscosity increases upon combination, precluding spray application
Solution Approach 1:
The patent extracts the polymerization initiation step from the application process by using a one-part formulation that only begins polymerizing after solvent evaporation. This separates the application phase (low viscosity) from the curing phase (high viscosity), enabling spray application without nozzle fouling.
Solution Approach 2:
The formulation uses solvent concentration as a control parameter, where the solvent keeps viscosity low during application and its evaporation triggers the polymerization reaction. This parameter change enables the formulation to transition from a sprayable state to a curing state without requiring separate mixing steps.
3Reliability
If higher molecular weight polymer precursors are used, then coating performance is improved, but the precursors are unable to permeate well into porous or scaly substrates
Solution Approach 1:
The patent uses a dynamic molecular weight approach where the formulation starts with low molecular weight monomers that can easily permeate substrates, and these monomers polymerize in situ to form high molecular weight crosslinked networks. This dynamic transformation allows both good substrate penetration and high coating performance.
Solution Approach 2:
The patent transitions from a single-molecular-weight approach to a distributed molecular weight approach, where monomers of various sizes are present in the formulation. This allows smaller molecules to penetrate substrates while larger polymer networks form the protective coating, effectively operating in multiple molecular weight dimensions simultaneously.
4Reliability
If surface preparation is performed to remove debris and grease, then coating adhesion is improved, but the process becomes more complex and time-consuming
Solution Approach 1:
The formulation contains built-in surface preparation capabilities through its chemical composition and application mechanism. The solvent component helps clean the surface during application, and the polymerization process creates strong adhesion without requiring extensive separate surface preparation steps.
Solution Approach 2:
The one-part formulation serves multiple functions simultaneously: it acts as a solvent, adhesion promoter, and polymerization initiator. This multi-functionality reduces the need for separate surface preparation steps while maintaining good coating adhesion across various substrate types.
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 formulation provides a stable, efficient, and effective coating that inhibits corrosion, even on porous substrates, with enhanced adhesion and durability, suitable for various surfaces including metals, concrete, and wood, and demonstrates superior performance in salt spray testing and environmental exposure.
Implementation Method 1
An organic solvent in which the polymerizable compound and the second polymerizable compound are soluble is present and provides storage stability and upon evaporation of the solvent, a rate of polymerization of the compound accelerates independent of addition of a second part
Implementation Method 2
A one part, storage stable polymerizable formulation includes a monomeric or oligomeric ethylenically unsaturated polymerizable compound... After allowing sufficient time and temperature for the solvent to evaporate to accelerate a rate of cure of the polymerizable compound, a polymerized coating on the article is formed
Data Source
AI summary
A one part, storage stable polymerizable formulation includes a monomeric or oligomeric ethylenically unsaturated polymerizable compound that is at least one of methacrylate esters of polyethylene glycols, 1,6-hexane diol, or polypropylene glycol, 1,3- and 1,4-butylene glycol trimethylol propane trimethacrylate, or ethoxylated bisphenol A dimethacrylate. A second polymerizable compound includes dicyclopentadiene modified oligomers. An organic solvent is present and provides storage stability and upon evaporation of the solvent, a rate of polymerization of the compound accelerates independent of addition of a second part. An alkyd is present that includes an unsaturated fatty acid. An optional additive of at least one of a transition metal cure accelerator, a filler, a plasticizer, a colorant, and a cure inhibitor is present. The formulation is at least 30 total weight percent solids. A process of forming a polymerized coating on an article is also provided.