Direct-to-Metal Non-Skid Coating with Siloxane Resin
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Solution Overview
Problem
Conventional non-skid coatings on U.S. Navy flight decks suffer from rapid degradation due to UV and visible radiation, loss of abrasive profile, and high volatile organic compound (VOC) levels, leading to performance failures such as cracking and loss of adhesion.
Innovation Solution
A non-skid coating formulation using amino-functional siloxane resin, non-aromatic epoxy resin, spherical filler, pigment, and coarse aggregate, which provides improved external durability, reduced VOC content, and direct-to-metal adhesion without the need for a primer, utilizing organo-siloxane chemistry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional aromatic epoxy resin and amine resin are used in non-skid coating, then the coating provides initial adhesion and hardness, but the coating rapidly degrades under UV and visible radiation with fading, chalking, and cracking
Solution Approach 1:
The patent employs a hybrid coating system combining inorganic siloxane resin with organic epoxy resin and amine resin. This composite material approach integrates the UV resistance and durability of siloxane (with stronger silicon-oxygen bonds) while maintaining the adhesion and flexibility provided by the organic components, thereby resolving the contradiction between initial coating performance and long-term UV durability
Solution Approach 2:
The patent modifies the chemical composition parameters by replacing traditional aromatic epoxy resins with non-aromatic cycloaliphatic epoxy resins. This parameter change eliminates the aromatic structure that is susceptible to UV degradation, thereby improving the coating's resistance to fading, chalking, and cracking while maintaining other performance characteristics
2Strength
If traditional aromatic epoxy resins are used, then the coating achieves adequate hardness, but the aromatic structure causes rapid fading and degradation under UV exposure
Solution Approach 1:
The patent changes the chemical structure parameter by substituting aromatic epoxy resins with non-aromatic cycloaliphatic epoxy resins. This eliminates the aromatic rings that absorb UV radiation and undergo degradation, thereby preventing fading and chalking while the siloxane-epoxy hybrid matrix maintains the required coating hardness through crosslinked network formation
3Strength
If conventional amine resins (e.g., amidoamine resin) are used, then the coating provides crosslinking and hardness, but yellowing occurs over time
Solution Approach 1:
The patent creates a composite curing system using siloxane-resin-based chemistry combined with modified amine resins. The siloxane component provides crosslinking through silicon-oxygen-silicon bonds that do not yellow, while the modified amine resins contribute to the crossnetwork structure without the severe yellowing tendency of traditional amidoamine resins, thus maintaining crosslinking density while improving color stability
4Ease of operation
If high levels of volatile organic compounds (VOCs) are used as solvents, then the coating achieves proper viscosity and application properties, but solvent entrapment, shrinkage, and cracking occur during curing
Solution Approach 1:
The patent changes the solvent system parameters by using low-VOC or high-solids formulations. The coating achieves proper viscosity through optimized resin molecular weight and structure rather than high solvent content, eliminating solvent entrapment and shrinkage issues while the siloxane-epoxy hybrid system provides sufficient workability and application properties with minimal VOCs
5Reliability
If non-skid coating is applied over anti-corrosive deck primer, then adhesion is provided, but the primer layer adds complexity and the coating may still lose adhesion over time
Solution Approach 1:
The patent develops a siloxane-modified epoxy coating formulation that provides direct-to-metal adhesion capability. The siloxane component enhances substrate bonding through chemical interaction with metal surfaces, while the epoxy matrix provides mechanical adhesion. This composite formulation eliminates the need for a separate primer layer, reducing system complexity while maintaining or improving adhesion performance through the synergistic action of siloxane and epoxy components
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 exhibits enhanced exterior durability, color retention, and chemical resistance, with reduced VOC levels and effective direct-to-metal adhesion, as demonstrated by improved performance in QUV-B exposure and chemical resistance tests, meeting U.S. Navy specifications.
Implementation Method 1
Hybrid coating technology based on the incorporation of silicone-based resins (e.g., siloxanes or silanes) with epoxy or amine chemistries
Implementation Method 2
Siloxane-based materials, which contain silicone-oxygen bonds, are becoming increasing popular within the global coatings market due to their outstanding external durability
Implementation Method 3
silicone-oxygen bonds are much stronger than the carbon-carbon and carbon-hydrogen bonds that are typically found in traditional non-skid coatings. This increased bond strength leads to a greater external durability and chemical resistance, thereby extending the life-cycle of a coating by preventing the rapid chalking, fading and/or cracking that occurs due to degradation by ultra-violet (UV) and visible radiation
Implementation Method 4
The coating is applied to the deck by a roller to create a rough 'peak and valley' profile, thereby providing a frictional surface to prevent the sliding, moving, or skidding of crew members, aircraft, storage containers, and machinery
Data Source
AI summary
A non-skid coating described herein attempts to overcome the deficiencies of the conventional coatings with improved external durability and color retention, a reduced level of VOCs, and direct-to-metal (DTM) adhesion using organo-siloxane chemistry. The non-skid coating has a first component having an amino-functional siloxane resin; a second component having a non-aromatic epoxy resin; a spherical filler for lowering viscosity; a pigment; a coarse aggregate; and a thixotropic agent. The amino-functional siloxane resin can be an amino-functional methyl phenyl polysiloxane, diphenyl polysiloxane or silsesquioxane-based resin. The non-aromatic epoxy resin can be cycloaliphatic or aliphatic. The first component is about 5% to 20% weight of the coating, and the second component is about 80% to 95% weight of the coating.