Sprayable Polymeric Coating for Complex Metal Structures
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Solution Overview
Problem
Conventional corrosion protection methods for metal structures, such as coatings and paints, are labor-intensive, environmentally harmful, and fail to effectively seal crevices in complex structures, leading to premature degradation and the need for frequent reapplication.
Innovation Solution
A sprayable polymeric coating system composed of cellulose acetate butyrate, epoxidized soy bean oil, a corrosion inhibitor, a dye, and a stabilizer, which can be quickly applied, dries rapidly, and is removable and reusable, providing long-lasting protection without the need for additional products or extensive surface preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coatings and paints are applied to protect metal structures, then corrosion protection is provided, but the coatings degrade after only six months due to their porous nature
Solution Approach 1:
The patent uses a composite material system combining polymeric resin (cellulose acetate butyrate), plasticizers (epoxidized fatty acid esters), corrosion inhibitors (epoxidized canola oil), and stabilizers (titanium dioxide or aluminum hydroxide). This composite formulation creates a non-porous, flexible coating that maintains its protective properties for over 30 years, resolving the contradiction between providing reliable corrosion protection and achieving long duration of action.
2Reliability
If conventional coatings are applied to complex structures with crevices, then surface coverage is attempted, but the paint cannot seal crevices where moisture pools
Solution Approach 1:
The patent employs a flexible polymeric coating system that can conform to complex structural shapes and completely seal crevices. The plasticizer components (epoxidized fatty acid esters) provide flexibility allowing the coating to adapt to irregular surfaces, bolted flanges, and operable components while maintaining a continuous protective barrier that prevents moisture accumulation in crevices.
3Reliability
If conventional coatings are applied to provide protection, then corrosion resistance is achieved, but the process is labor intensive and requires extensive time for application, curing, and drying
Solution Approach 1:
The patent utilizes parameter changes in the coating formulation, specifically using cellulose acetate butyrate with controlled plasticizer content (epoxidized fatty acid esters) and corrosion inhibitors (epoxidized canola oil), which enables the coating to cure rapidly. The coating transitions from liquid to solid state quickly, reducing application and curing time to under 8 hours while maintaining reliable corrosion protection.
4Ease of repair
If conventional coatings are removed and reapplied for repair, then protection is restored, but the removal process damages the surface and creates hazardous waste
Solution Approach 1:
The patent describes a coating system that can be easily removed and reapplied without damaging the underlying metal surface. The coating formulation (cellulose acetate butyrate-based with epoxidized plasticizers and inhibitors) allows for simple removal processes that do not require harsh solvents or abrasive tools, eliminating hazardous waste generation while maintaining ease of repair capability.
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 system offers extended protection for over 30 years, is ecologically safe, and can be easily repaired, reducing waste and maintenance costs while maintaining integrity across temperature variations and complex structural shapes.
Implementation Method 1
The corrosion inhibitor is an epoxidized canola oil
Implementation Method 2
The plasticizer is an epoxidized fatty acid ester
Implementation Method 3
a cellulose acetate buterate, a plasticizer, a corrosion inhibitor, an epoxidized soil bean oil, a dye, and a stabilizer
Data Source
AI summary
A method of applying a protective polymeric coating to a substrate has the steps of mixing a cellulose acetate buterate and a plasticizer and a corrosion inhibitor together to form a solid mixture, heating the solid mixture so as to form a liquid state, painting the substrate with the liquid state, and drying the liquid state on the substrate for a period of time. The step of painting can include spraying the liquid state of the mixture onto the substrate. The plasticizer is an epoxidized fatty acid ester. The corrosion inhibitor is epoxidized canola oil. Additionally, epoxidized soil bean oil, silica amorphous and titanium dioxide can be mixed together.