Swellable Powder Coating for Corrosion Protection

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Solution Overview

Problem

Existing anti-corrosion coatings, especially those using superabsorbent polymers, face issues with low mechanical resistance and high swelling pressure when damaged, leading to reduced effectiveness and increased maintenance needs.

Innovation Solution

A substrate with a swellable coating system featuring a thermoplastic or thermoplastic-elastic matrix material incorporating a swellable substance that automatically seals damages upon contact with liquid, minimizing corrosion progression and extending protection duration, applied using powder coating methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If superabsorbent polymers are added to liquid protective coatings to improve corrosion protection, then ion permeability is reduced and protective effect is improved, but mechanical resistance and resistance to mechanical damage decrease

Engineering Contradiction:

Improvecorrosion protection effectVSAvoidmechanical resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the physical state of the coating material from liquid to powder form. This parameter change allows the coating to achieve both the corrosion protection benefits of superabsorbent polymers and the mechanical strength of powder coatings, resolving the contradiction between improved corrosion protection and reduced mechanical resistance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite powder coating material combining thermoplastic or thermoplastic-elastic binder with superabsorbent polymer particles. This composite structure allows the coating to simultaneously provide mechanical protection from the thermoplastic matrix and corrosion protection through the swelling action of SAP particles, addressing both requirements

Inventive Principle:

Principle #40Composite materials

2Reliability

If superabsorbent polymers are used in protective coatings to reduce ion permeability, then corrosion protection is improved, but swelling pressure upon contact with liquids increases causing mechanical damage

Engineering Contradiction:

Improvecorrosion protectionVSAvoidswelling pressure damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses the elastic thermoplastic-elastic binder as a cushioning matrix that absorbs and distributes the swelling pressure of SAP particles before it can cause mechanical damage. This beforehand cushioning prevents the harmful effects of swelling pressure while maintaining the beneficial corrosion protection

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent selects thermoplastic-elastic materials with specific elasticity parameters that can accommodate the swelling pressure of SAP particles. By carefully selecting materials with appropriate elastic properties, the coating can withstand the swelling pressure without suffering mechanical damage

Inventive Principle:

Principle #35Parameter changes

3Reliability

If liquid coating materials with superabsorbent polymers are used to achieve corrosion protection, then protective effect is improved, but curing time increases and application process becomes complex

Engineering Contradiction:

Improvecorrosion protection effectVSAvoidcuring time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the chemical curing process of liquid coatings with the physical sintering process of powder coatings. This substitution eliminates long curing times and complex application processes while maintaining effective corrosion protection, as the powder coating forms a protective film through melting and sintering rather than chemical curing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the coating material from liquid to powder form, which fundamentally alters the application and curing parameters. Powder coatings can be applied as dry powder and cured rapidly through sintering, eliminating the long curing times associated with liquid coating curing processes

Inventive Principle:

Principle #35Parameter changes

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 provides effective self-sealing and extended anti-corrosion protection with reduced environmental impact and maintenance requirements, maintaining integrity even after mechanical damage.

Implementation Method 1

the functional layer comprises at least one thermoplastic and/or thermoplastic-elastic matrix material, at least one swellable substance embedded in the matrix material

Methodology Applied

Scientific EffectSwelling: Absorption (physical)

Implementation Method 2

applied using powder coating methods

Methodology Applied

Scientific EffectPowder coating deposition: Deposition (physical)

Data Source

PatentEP3350269B1Substrate and/or base with swellable coating

Publication Date: 2020.06.03 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

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AI summary

The invention relates to a substrate (2) and/or substructure having a swellable coating system (1) as a protective coating, wherein the coating system (1) comprises at least one functional layer (3), the functional layer (3) is obtained by applying a powdery coating material to the substrate (2) and/or the substructure, and the coating material contains at least one thermoplastic or thermoplastic-elastic matrix material and at least one swellable substance.