Water-Based Inorganic Zinc Anti-Rust Coating Composition
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Solution Overview
Problem
Conventional water-based inorganic zinc anti-rust coatings lack sufficient electric anticorrosion resistance and weldability, making them unsuitable for environments exposed to seawater or requiring electric anticorrosion protection and welding processes.
Innovation Solution
An anti-rust coating composition comprising silica nanoparticles, zinc-based powders, aluminum phosphate-based compounds, conductive pigments, and water, with a specific mass ratio of zinc-based powder to aluminum phosphate-based compound and conductive pigment, which forms a coating film that provides excellent electric anticorrosion resistance and weldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If water-based inorganic zinc anti-rust coating is used to reduce volatile organic solvent emissions, then environmental load is reduced, but electric anticorrosion resistance becomes insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the water-based coating by incorporating aluminum phosphate-based compounds and conductive pigments in specific ratios. This modifies the electrochemical properties of the coating film, enabling it to achieve sufficient electric anticorrosion resistance while maintaining water-based formulation that reduces VOC emissions.
Solution Approach 2:
The patent creates a composite coating system by combining water-based inorganic zinc anti-rust coating with aluminum phosphate-based compounds and conductive pigments. This composite formulation integrates multiple functional components: zinc powder for sacrificial protection, aluminum phosphate for corrosion resistance, and conductive pigments for electrical conductivity, achieving both environmental compliance and performance requirements.
2Object-generated harmful factors
If water-based inorganic zinc anti-rust coating is applied, then volatile organic solvent content is reduced, but weldability deteriorates due to increased welding defects
Solution Approach 1:
The patent adjusts the compositional parameters of the water-based coating, specifically controlling the ratio of zinc-based powder to aluminum phosphate-based compound and conductive pigment. This optimization ensures the coating provides adequate protection during welding while maintaining the environmental benefits of water-based formulation.
Solution Approach 2:
The patent creates localized functional zones within the coating film through the specific composition ratio. The aluminum phosphate-based compound and conductive pigment are distributed to create regions that enhance weldability without compromising the overall corrosion protection, allowing the coating to perform differently in different functional zones.
3Device complexity
If water-based inorganic zinc anti-rust coating is used as a single coating film, then construction steps are simplified, but anti-rust properties in corrosive environments become insufficient
Solution Approach 1:
The patent designs the water-based inorganic zinc anti-rust coating to perform multiple functions simultaneously: primary corrosion protection through zinc sacrificial action, enhanced anti-rust properties through aluminum phosphate-based compounds, and improved durability through conductive pigments. This multi-functional single-coating system eliminates the need for additional topcoats while providing comprehensive protection in corrosive environments.
Solution Approach 2:
The patent formulates a composite single-coating system that integrates zinc-based powder for galvanic protection, aluminum phosphate-based compounds for chemical corrosion resistance, and conductive pigments for electrical conductivity. This composite formulation within a single coating layer provides the anti-rust properties of multiple coating systems while simplifying the overall coating structure.
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 composition achieves enhanced electric anticorrosion resistance and weldability as a single coating film, comparable to solvent-based inorganic zinc anti-rust coatings, while reducing volatile organic solvent emissions.
Implementation Method 1
a sacrificial anode (not shown in the figure) made of zinc or the like is connected to the steel rebar 12, so that the zinc functions as a galvanic anode
Implementation Method 2
a conductive pigment (D); and water, wherein the mass ratio [(B)/{(C) + (D)}] of the zinc-based powder (B) to the total of the aluminum phosphate-based compound (C) and the conductive pigment (D) is 7.0 or less and wherein the conductive pigment (D) is zinc oxide
Implementation Method 3
an inorganic zinc primary anti-rust coating containing a siloxane-based binder and a zinc powder are known
Implementation Method 4
the zinc functions as a galvanic anode and undergoes oxidation reactions such as the following (1) and (2) to generate electrons
Implementation Method 5
an aluminum phosphate-based compound (C)
Data Source
Figure 1~1(c)
Figure 2~2(c)
AI summary
An anti-rust coating composition including: a binder (A) including silica nanoparticles; at least one zinc-based powder (B) selected from a zinc powder and a zinc alloy powder; an aluminum phosphate-based compound (C); a conductive pigment (D); and water, wherein a mass ratio [(B)/{(C) + (D)}] of the zinc-based powder (B) to a total of the aluminum phosphate-based compound (C) and the conductive pigment (D) is 0.1 to 7.0.