Pipe Support Coating Composition for Crevice Corrosion Protection

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Solution Overview

Problem

Existing corrosion protection methods for metal structures, particularly in submerged environments, are ineffective as they degrade quickly, require labor-intensive application and removal, and often result in ecological harm, with crevice corrosion under pipe supports being particularly challenging to address without shutting down operations.

Innovation Solution

A coating composition comprising cellulose acetate, a plasticizer, an oil, and an ethylene-based polymer stabilizer is applied as a liquid state to the joinder of pipes and pipe supports, which dries quickly and forms a flexible, corrosion-resistant membrane that encapsulates the area, allowing for continued operation without lifting pipes or removing clamps, and provides long-term protection against corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional protective coatings are applied to metal structures, then corrosion protection is provided, but the coatings degrade quickly (after six months) and require frequent reapplication

Engineering Contradiction:

Improvecorrosion protection durabilityVSAvoidcoating service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent uses a removable protective coating that is intentionally designed to be temporary and easily replaceable. The coating provides short-term corrosion protection during critical periods, then can be removed and reapplied as needed, accepting that the coating itself has limited durability but serving its protective function effectively during its service life.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the physical and chemical parameters of the coating formulation to achieve rapid drying and flexible membrane formation. By adjusting composition parameters and applying heat during the process, the coating transitions from a liquid state to a durable flexible membrane that provides long-term corrosion protection without requiring frequent reapplication.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional coatings are applied and cured, then corrosion protection is achieved, but the process requires excessive time (in excess of eight hours) and operational shutdowns

Engineering Contradiction:

Improvecorrosion protectionVSAvoidcoating application and curing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent implements a multi-stage coating process with periodic actions: initial application, heating phase, drying phase, and final curing. Each stage is optimized to occur in rapid succession, with the heating and drying phases significantly reducing total processing time compared to conventional single-stage curing processes that require hours of continuous operation.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent performs preliminary surface preparation and coating application in a controlled manner before final curing. By preparing the surface and applying the coating to the correct thickness beforehand, the subsequent heating and drying phases can proceed rapidly without requiring extended curing times, thus reducing overall process time while maintaining protection quality.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If protective coatings are applied to pipes and supports, then corrosion protection is provided, but the application and removal processes are labor intensive and costly

Engineering Contradiction:

Improvecorrosion protectionVSAvoidcoating application ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical application methods with a spray application system that can be easily controlled and removed. The coating is applied as a spray that can be precisely targeted and then rapidly dried and cured, eliminating the need for labor-intensive manual coating application and subsequent mechanical removal processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If conventional coatings are used, then some corrosion protection is provided, but they cannot cover crevices and seal crevice areas effectively

Engineering Contradiction:

Improvecorrosion protectionVSAvoidcoating coverage capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent creates a flexible membrane coating that can conform to complex geometries and crevice areas. The flexible nature of the cured coating allows it to seal around pipes, supports, and clamps, providing protection in crevice areas that rigid conventional coatings cannot reach or seal effectively.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses a composite coating formulation containing cellulose acetate, plasticizer, oil, and ethylene-based polymer stabilizer that creates a flexible, adhesive membrane. This composite material combines the properties of different components to achieve both adhesion to metal surfaces and flexibility to conform to crevice geometries, providing comprehensive corrosion protection in difficult-to-reach areas.

Inventive Principle:

Principle #40Composite materials

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, reduces friction, and extends asset lifespan without operational shutdowns, minimizing ecological impact and labor costs, while allowing for easy inspection and flexibility to accommodate thermal expansion and vibration.

Implementation Method 1

drying the liquid state on the area of the joinder

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

forms a flexible, corrosion-resistant membrane that encapsulates the area

Methodology Applied

Scientific EffectEncapsulation: Physical Containment

Implementation Method 3

reduces friction

Methodology Applied

Scientific EffectLubrication: Lubrication

Implementation Method 4

provides long-term protection against corrosion

Methodology Applied

Scientific EffectCorrosion resistance:

Data Source

PatentUS10913861B2Pipe and pipe support protection process and composition therefor

Publication Date: 2021.02.09 OXIFREE GLOBAL LTD

AI summary

A process and composition for coating a pipe and a pipe support includes mixing a cellulose acetate, a plasticizer, and an oil together so as to form a solid mixture, heating the solid mixture so as to form a liquid state, covering an area of the joinder of the pipe and the pipe support with the liquid state, and drying the liquid state on the area of the joinder. An ethylene-based polymer stabilizer is added to the mixture of the cellulose acetate, the plasticizer and the oil. The oil migrates by gravity from the liquid state from the covered pipe into an area of contact between the pipe and the pipe support. The liquid state is applied around the outer diameter of the pipe and over the outer surface of the pipe support underlying the outer diameter of the pipe.