WO2019245326A1 - Anti-corrosive coating composition and anti-corrosive layer using the same - Google Patents
Anti-corrosive coating composition and anti-corrosive layer using the same Download PDFInfo
- Publication number
- WO2019245326A1 WO2019245326A1 PCT/KR2019/007512 KR2019007512W WO2019245326A1 WO 2019245326 A1 WO2019245326 A1 WO 2019245326A1 KR 2019007512 W KR2019007512 W KR 2019007512W WO 2019245326 A1 WO2019245326 A1 WO 2019245326A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- coating composition
- corrosive coating
- corrosive
- liquid
- content
- Prior art date
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- 239000008199 coating composition Substances 0.000 title claims abstract description 77
- 239000007788 liquid Substances 0.000 claims abstract description 50
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 32
- -1 alkyl silicate Chemical compound 0.000 claims abstract description 29
- 229920005989 resin Polymers 0.000 claims abstract description 26
- 239000011347 resin Substances 0.000 claims abstract description 26
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- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 19
- 235000019832 sodium triphosphate Nutrition 0.000 claims abstract description 19
- UNXRWKVEANCORM-UHFFFAOYSA-I triphosphate(5-) Chemical compound [O-]P([O-])(=O)OP([O-])(=O)OP([O-])([O-])=O UNXRWKVEANCORM-UHFFFAOYSA-I 0.000 claims abstract description 19
- 239000002904 solvent Substances 0.000 claims description 37
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 34
- 239000000049 pigment Substances 0.000 claims description 21
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- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 claims description 14
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- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 claims description 2
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 2
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- JCDCUOAMVBQBTH-UHFFFAOYSA-N tetrabutoxy silicate Chemical compound CCCCOO[Si](OOCCCC)(OOCCCC)OOCCCC JCDCUOAMVBQBTH-UHFFFAOYSA-N 0.000 claims description 2
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
- C09D5/10—Anti-corrosive paints containing metal dust
- C09D5/106—Anti-corrosive paints containing metal dust containing Zn
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
- C09D183/02—Polysilicates
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
- C09D5/082—Anti-corrosive paints characterised by the anti-corrosive pigment
- C09D5/084—Inorganic compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
- C09D5/10—Anti-corrosive paints containing metal dust
- C09D5/103—Anti-corrosive paints containing metal dust containing Al
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/60—Additives non-macromolecular
- C09D7/61—Additives non-macromolecular inorganic
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/60—Additives non-macromolecular
- C09D7/63—Additives non-macromolecular organic
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/66—Additives characterised by particle size
- C09D7/69—Particle size larger than 1000 nm
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/08—Metals
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/49—Phosphorus-containing compounds
- C08K5/51—Phosphorus bound to oxygen
- C08K5/52—Phosphorus bound to oxygen only
- C08K5/521—Esters of phosphoric acids, e.g. of H3PO4
Definitions
- the present invention relates to an anti-corrosive coating composition having improved weldability and anti-corrosivity, and an anti-corrosive layer formed from the same.
- An anti-corrosive coating composition is generally referred to as a shop primer, a prefabrication primer, or a first anti-corrosive primer.
- Such an anti-corrosive coating composition is used to coat steel, which is a base material of a steel structure, to prevent the steel structure from being exposed to the atmosphere and corroding.
- High zinc content paints which contain a large amount of a zinc powder and a binder, among the above are widely used as temporary anti-corrosive paints for large steel reinforcing structures such as ships, bridges, and the like.
- the zinc powder contained in the high zinc content paints improves the anti-corrosivity, it increases zinc salts at the same time, which reduces the attachability to an overcoating composition coated thereon.
- gases and fumes generated when zinc is vaporized or oxidized during welding increase the generation of such defects as pits and blowholes.
- VOCs volatile organic compounds
- An object of the present invention is to provide an anti-corrosive coating composition and an anti-corrosive layer formed from the same, which have improved corrosivity and weldability even with the same or a thinner thickness of a coating layer and can reduce VOCs emissions by lowering the total amount of paint used.
- the present invention provides an anti-corrosive coating composition, which comprises a first liquid and a second liquid, wherein the first liquid comprises an alkyl silicate resin; the second liquid comprises a zinc powder and aluminum tripolyphosphate; and the content of the zinc powder is in a range of 18 to 40% by weight based on the total weight of the anti-corrosive coating composition.
- the present invention provides an anti-corrosive layer formed from the anti-corrosive coating composition.
- the anti-corrosive coating composition according to the present invention has improved anti-corrosivity and weldability even with the same or a thinner thickness of a coating layer.
- the anti-corrosive coating composition according to the present invention can reduce the thickness of a coating layer, whereby the amount of an organic solvent to be used is lowered, and it is environmentally friendly since the VOCs emissions can be reduced.
- the present invention provides an anti-corrosive coating composition having improved weldability and anti-corrosivity, and an anti-corrosive layer formed from the same.
- the anti-corrosive coating composition according to an embodiment comprises a first liquid and a second liquid.
- the anti-corrosive coating composition is a two-part type, anti-corrosive coating composition.
- the first liquid comprises an alkyl silicate resin.
- the alkyl silicate resin employed in the anti-corrosive coating composition of the present invention serves to directly bond to the zinc powder and steel to enhance attachability and adhesiveness.
- the content of the alkyl silicate resin is 10 to 40% by weight based on the total weight of the first liquid. Specifically, the content of the alkyl silicate resin may be 15 to 30% by weight or 20 to 30% by weight based on the total weight of the first liquid, but it is not limited thereto.
- the content of the alkyl silicate resin is 5 to 20% by weight based on the total weight of the anti-corrosive coating composition. Specifically, the content of the alkyl silicate resin may be 5 to 15% by weight or 8 to 12% by weight based on the total weight of the anti-corrosive coating composition, but it is not limited thereto.
- the content of the alkyl silicate resin satisfies the above ranges, there is an advantageous effect on the attachability to steel and the anti-corrosivity. Specifically, if the content of the alkyl silicate resin is less than 5% by weight based on the total weight of the anti-corrosive coating composition, the attachability to steel is poor. If the content exceeds 20% by weight, the anti-corrosivity is deteriorated.
- the alkyl silicate resin is at least one selected from the group consisting of tetramethoxy silicate, tetraethoxy silicate, tetrapropoxy silicate, tetraisopropoxy silicate, tetrabutoxy silicate, tetramethyl orthosilicate, tetraethyl orthosilicate, tetra-n-propyl orthosilicate, tetraisopropyl orthosilicate, tetra-n-butyl orthosilicate, tetra-sec-butyl orthosilicate, methyl polysilicate, and ethyl polysilicate.
- the alkyl silicate resin may be a hydrolysis condensate of an alkyl silicate.
- the alkyl silicate resin has a silica content of 20 to 60% by weight. Specifically, the alkyl silicate resin may have a silica content of 25 to 50% by weight or 30 to 40% by weight, but it is not limited thereto.
- the alkyl silicate resin has an acidity of 0.01 to 100 ppm. Specifically, the alkyl silicate resin may have an acidity of 0.01 to 20 ppm or 0.1 to 10 ppm, but it is not limited thereto.
- the alkyl silicate resin has a viscosity of 2 to 10 cps at 25°C. Specifically, the alkyl silicate resin may have a viscosity of 3 to 8 cps or 4 to 6 cps, but it is not limited thereto.
- the alkyl silicate resin has a specific gravity of 0.9 to 1.1. Specifically, the alkyl silicate resin may have a specific gravity of 0.95 to 1.1 or 1.0 to 1.1, but it is not limited thereto.
- the first liquid may further comprise a first solvent in addition to the alkyl silicate resin.
- the first solvent contained in the anti-corrosive coating composition serves to improve the wettability and workability and to contribute to hydrolysis, thereby controlling the pot life and storability.
- the first solvent is not particularly limited, specifically, solvents commonly used in the field of coatings such as water, alcohol-based solvents, ester-based solvents, ketone-based solvents, aromatic-based solvents, glycol-based solvents, or the like may be used.
- Examples of the alcohol-based solvent include methanol, ethanol, isopropanol, and butanol.
- Examples of the ester-based solvent include ethyl acetate and butyl acetate.
- Examples of the ketone-based solvent include methyl isobutyl ketone and cyclohexanone.
- Examples of the aromatic-based solvent include benzene, xylene, and toluene.
- Examples of the glycol-based solvent include propylene glycol monomethyl ether and propylene glycol monomethyl ether acetate.
- the first solvent may be used alone or in combination of two or more.
- the first liquid may further comprise an acid catalyst or an accelerator.
- the first liquid may further comprise an acid catalyst and an accelerator.
- the acid catalyst and the accelerator are used for expediting the hydrolysis reaction and serve to strengthen the strength at the same time.
- An inorganic acid, an organic acid, or the like may be used as the acid catalyst.
- the inorganic acid include hydrochloric acid, hydrofluoric acid, hydrobromic acid, hydroiodic acid, sulfuric acid, sulfurous acid, nitric acid, nitrous acid, chloric acid, perchloric acid, and phosphoric acid.
- the organic acid include acetic acid, propionic acid, stearic acid, phthalic acid, and salicylic acid. These may be used alone or in combination of two or more.
- the acid catalyst is generally somewhat slow and proceeds in a more controlled manner as compared with partial decomposition by a base.
- the presence of an acid tends to stabilize the reactive silanol (Si-OH) functional groups and to increase the storage stability.
- Zinc chloride, magnesium chloride, dibutyltin laurate, dioctyltin laurate, or the like may be used as the accelerator.
- the maximum amount of the accelerator to be added is limited by the fast cure that negatively affects the cracking level (or internal stress).
- the second liquid comprises a zinc powder and aluminum tripolyphosphate.
- the zinc powder contained in the anti-corrosive coating composition serves as an anti-corrosive pigment for preventing the top coat from rusting.
- Zinc has a higher tendency to ionize than iron, so it has the effect of preventing corrosion of iron as its corrosion occurs in advance in a corrosive environment.
- the zinc powder may have various shapes such as a spherical shape, a slightly irregular particle shape, a flake shape, a disk shape, a needle shape, a plate shape, a fiber shape, a rod shape, and the like.
- the zinc powder may have a spherical shape.
- the spherical shape refers to a shape approximate to a sphere.
- the aspect ratio does not have a specifically defined range, but it is preferably about 1 to 3.
- the zinc powder has an average particle diameter of 1 to 20 ⁇ m. Specifically, the zinc powder has an average particle diameter of 1 to 10 ⁇ m, 2 to 8 ⁇ m, or 3 to 6 ⁇ m, but it is not limited thereto.
- the content of the zinc powder is in a range of 18 to 40% by weight based on the total weight of the anti-corrosive coating composition.
- the content of the zinc powder may be in a range of 18 to 40% by weight, 19 to 40% by weight, or 19 to 38% by weight, based on the total weight of the anti-corrosive coating composition, but it is not limited thereto.
- the content of the zinc powder is in a range of 40 to 70% by weight based on the total weight of the solids content of the anti-corrosive coating composition.
- the content of the zinc powder is in the above ranges, there is an advantageous effect in terms of the anti-corrosivity, attachability, precipitation problem, and the like. Specifically, if the content of the zinc powder is less than 40% by weight based on the total weight of the solids content of the anti-corrosive coating composition, the anti-corrosivity is deteriorated. If it exceeds 70% by weight, zinc salts increase, so that the attachability to an overcoat may be deteriorated and a precipitation problem may occur.
- the aluminum tripolyphosphate contained in the anti-corrosive coating composition, together with the zinc powder, produces the effect of significantly enhancing the anti-corrosivity of a coating layer.
- the content of the aluminum tripolyphosphate is in a range of 2 to 12% by weight based on the total weight of the anti-corrosive coating composition.
- a thin coating layer having a thickness of 5 to 30 ⁇ m, specifically 8 to 10 ⁇ m, may have excellent anti-corrosivity.
- the content of P 2 O 5 in the aluminum tripolyphosphate is 30 to 90% by weight. Specifically, the content of P 2 O 5 in the aluminum tripolyphosphate may be 45 to 80% by weight or 50 to 70% by weight, but it is not limited thereto.
- the content of Al 2 O 3 in the aluminum tripolyphosphate is 10 to 40% by weight. Specifically, the content of Al 2 O 3 in the aluminum tripolyphosphate may be 15 to 30% by weight or 15 to 20% by weight, but it is not limited thereto.
- the aluminum tripolyphosphate may have a specific gravity of 2.5 to 3.5. Specifically, the aluminum tripolyphosphate may have a specific gravity of 2.8 to 3.2 or 2.9 to 3.1, but it is not limited thereto.
- the aluminum tripolyphosphate has an oil absorption of 10 to 70 ml/100 g. Specifically, the aluminum tripolyphosphate may have an oil absorption of 35 to 60 ml/100 g or 40 to 50 ml/100 g, but it is not limited thereto.
- the second liquid may further comprise an extender pigment.
- the extender pigment is intended to maintain the thickness of a coating layer or to increase the mechanical properties thereof. It produces the effect of improving such physical properties of a coating layer as hardness and adjusting the rheology thereof.
- the extender pigment is not particularly limited, and a pigment widely used in coating compositions may be generally used. Specifically, it may be at least one selected from the group consisting of calcium carbonate, clay, talc, silica, mica, barium sulfate, potassium feldspar, soda feldspar, calcium feldspar, dolomite, zirconium silicate, zinc oxide, kaolin, wollastonite, and diatomaceous earth, but it is not limited thereto.
- the content of the extender pigment is in a range of 0.2 to 15% by weight based on the total weight of the anti-corrosive coating composition.
- the content of the extender pigment is in the above range, there is an advantageous effect of appropriately forming a coating layer and maintaining the hardness thereof.
- the second liquid may further comprise a coloring pigment.
- the coloring pigment is intended to impart the necessary color to the anti-corrosive layer to be formed.
- the coloring pigment is not particularly limited, and a pigment widely used in coating compositions may be generally used. Specifically, it may be at least one selected from the group consisting of titanium oxide, Bengala, iron oxide, carbon black, copper-chrome-based black pigments, phthalocyanine green, phthalocyanine blue, cobalt blue, organic synthetic pigments, and organic-inorganic synthetic pigments, but it is not limited thereto.
- the second liquid may further comprise zinc oxide or zinc phosphate.
- the zinc oxide or zinc phosphate contained in the anti-corrosive coating composition together with the zinc powder and aluminum tripolyphosphate, supplementarily produces the effect of enhancing the anti-corrosivity of a coating layer.
- the median diameter (D50) of the zinc oxide or zinc phosphate is 1 ⁇ m to 20 ⁇ m. Specifically, the median diameter (D50) of the zinc oxide or zinc phosphate may be 1 ⁇ m to 10 ⁇ m or 1 ⁇ m to 5 ⁇ m, but it is not limited thereto.
- the zinc oxide or zinc phosphate has a specific gravity of 3.0 to 6.0. Specifically, the zinc oxide or zinc phosphate may have a specific gravity of 5.3 to 5.9 or 3.0 to 3.6, but it is not limited thereto.
- the zinc oxide or zinc phosphate has a water content of 0.01 to 3.0% by weight.
- the zinc oxide or zinc phosphate may have a water content of 0.01 to 0.3 % by weight or 1.0 to 3.0% by weight, but it is not limited thereto.
- the content of the zinc oxide and zinc phosphate is in a range of 1 to 5% by weight based on the total weight of the anti-corrosive coating composition.
- the second liquid may further comprise an additive.
- the additive is used as a material for improving the performance of a coating or a coating layer or for maintaining it to be constant. Those conventionally used in the coating compositions may be used.
- the additive may be a thickener, an anti-settling agent, a drying agent, a flow control agent, a defoaming agent, a dispersant, a color separation inhibitor, a skinning inhibitor, a sagging inhibitor, a plasticizer, an ultraviolet absorbent, or the like.
- the additive may be used alone or in combination of two or more.
- the anti-settling agent may be an organic bentonite type, an oxidized polyethylene type, a fumed silica type, an amide type, or the like, but it is not limited thereto.
- the dispersant may be a polyurethane type, a polyacrylic type, a controlled polymerization technology (CPT) type, a fatty acid type, a phosphoric acid ester type, or the like, but it is not limited thereto.
- CPT controlled polymerization technology
- the drying agent may be silica gel, aluminum oxide, zeolite, or the like, but it is not limited thereto.
- the ultraviolet absorbent may be a benzophenone type, a benzotriazole type, a salicylic acid type, an acrylonitrile type, an organic nickel compound, a monobenzoic acid type, or the like, but it is not limited thereto.
- the second liquid may further comprise a second solvent.
- the second solvent contained in the anti-corrosive coating composition serves to improve the wettability and workability and to stabilize the physical properties of the coating and helps disperse the pigment and the like.
- the second solvent is not particularly limited, specifically, solvents commonly used in the field of coatings such as water, alcohol-based solvents, ester-based solvents, ketone-based solvents, aromatic-based solvents, glycol-based solvents, or the like may be used.
- the second solvent may be used alone or in combination of two or more.
- the second solvent may be the same as, or different from, the first solvent.
- the content of the first solvent and the second solvent is 20 to 60% by weight based on the total weight of the anti-corrosive coating composition.
- the content of the first solvent and the second solvent may be 30 to 50% by weight or 40 to 50% by weight based on the total weight of the anti-corrosive coating composition, but it is not limited thereto.
- the second liquid may further comprise an extender pigment; zinc oxide or zinc phosphate; an additive; and a second solvent.
- the first liquid has a viscosity of 8 to 16 seconds at 25°C as measured by the flow cup method (ASTM D5125). Specifically, the first liquid may have a viscosity of 9 to 11 seconds or 12 to 14 seconds at 25°C, but it is not limited thereto.
- the second liquid has a viscosity of 70 to 100 KU at 25°C.
- the second liquid may have a viscosity of 75 to 85 KU or 85 to 95 KU at 25°C, but it is not limited thereto.
- the viscosities of the first liquid and the second liquid are in the above ranges, it is possible to form a coating layer with a small amount of a diluting solvent, thereby reducing VOCs.
- the volume ratio of the first liquid to the second liquid is in a range of 65:35 to 50:50.
- the volume ratio of the first liquid to the second liquid may be in a range of 60:40 to 50:50 or 55:45 to 50:50, but it is not limited thereto.
- volume ratio of the first liquid to the second liquid is in the above range, there is an advantageous effect on the attachability to steel and the anti-corrosivity.
- the anti-corrosive coating composition is characterized in that it does not contain a powder that contains Li 2 O, Na 2 O, and K 2 O. If the anti-corrosive coating composition contains a powder that contains Li 2 O, Na 2 O, and K 2 O, pinholes may be generated when a thin coating layer is formed, thereby causing the problem that the anti-corrosivity is deteriorated.
- the degree of rusting of the anti-corrosive coating composition may be 5 or higher. Specifically, the degree of rusting of the anti-corrosive coating composition may be 5 to 10, 6 to 10, 7 to 10, or 8 to 10, but it is not limited thereto.
- the degree of rusting of the anti-corrosive coating composition satisfies the above range, it indicates that the anti-corrosivity is comparatively good as the rusted area is 3% or less of the total area.
- the anti-corrosive coating composition does not contain an epoxy resin or the like, it falls under an inorganic anti-corrosive coating composition, which is different from organic anti-corrosive coating compositions conventionally used.
- the present invention provides an anti-corrosive layer formed from the anti-corrosive coating composition.
- the anti-corrosive layer is formed by the steps of: applying the anti-corrosive coating composition; curing the applied coating composition to form anti-corrosive coating layer; and the like.
- the anti-corrosive coating composition is applied onto the surface of a substrate such as a steel plate by a conventionally known method such as air spraying, airless spraying, or the like to form an uncured coating layer.
- a coating composition is applied in shipyards or steel mills, an airless sprayer or a line coating machine is mainly used as the application machine.
- the line coating machine manages the film thickness with the line speed, coating pressure of an air spray, an airless spray, or the like provided in the machine, and spray tip size (i.e., diameter).
- the curing temperature (or drying temperature) is usually 5 to 40°C, preferably 10 to 30°C, and the curing time (or drying time) is usually 3 to 15 minutes, specifically 5 to 10 minutes, but they are not limited thereto.
- the thickness of the dried anti-corrosive layer is preferably 5 to 15 ⁇ m. Specifically, the thickness of the anti-corrosive layer is preferably 6 to 15 ⁇ m, 6 to 12 ⁇ m, 6 to 10 ⁇ m, 7 to 15 ⁇ m, 7 to 12 ⁇ m, 7 to 10 ⁇ m, 8 to 15 ⁇ m, 8 to 12 ⁇ m, 8 to 10 ⁇ m, or 8 to 9.5 ⁇ m.
- the thickness of the anti-corrosive layer is in the above range, it is environmentally friendly since the generation of VOCs is reduced by 10 to 50% as compared with typical anti-corrosive coating compositions. Specifically, if the thickness is less than the above range, it is difficult to form a uniform coating layer and the anti-corrosivity is poor. If it exceeds the above range, the amount of the coating composition to be used increases, which is uneconomical, and the dryness and crack resistance of the coating layer are poor.
- the anti-corrosive layer is formed from the anti-corrosive coating composition in which the first liquid and the second liquid having the compositions as described above are mixed, so that it is excellent in denseness and attachability.
- DFT dry film thickness
- Tetraethoxysilicate as an alkyl silicate resin and an alcohol solvent, a glycol solvent, and water as a first solvent were mixed, and then a small amount of an acid catalyst and zinc chloride was added thereto, which was stirred for 90 minutes to prepare a first liquid.
- a spherical zinc powder, aluminum tripolyphosphate, zinc oxide, an extender pigment, an additive, an aromatic type solvent, an alcohol type solvent, and a glycol type solvent as a second solvent were mixed, which was dispersed and stirred for 120 minutes to prepare a second liquid.
- the average thickness of a dried coating layer was measured using an Elcometer 456 instrument.
- the thickness of the coating layer on the tin-plate (a flat plate for measurement of the thickness of a coating layer) was measured 10 times, and the average value was calculated as the average thickness of the coating layer.
- a salt spray test was conducted for 30 days according to ASTM B117 in order to measure the anti-corrosivity of the dried layers.
- the degree of rusting was measured comparatively. Evaluation of the degree of rusting was carried out according to the ASTM D610 evaluation standard described below.
- the rusted surface is 0.01% or less of the entire tested surface
- the rusted surface is greater than 0.01% up to 0.03% of the entire tested surface
- the rusted surface is greater than 0.03% up to 0.1% of the entire tested surface
- the rusted surface is greater than 0.1% up to 0.3% of the entire tested surface
- the rusted surface is greater than 0.3% up to 1% of the entire tested surface
- the rusted surface is greater than 1% up to 3% of the entire tested surface
- the rusted surface is greater than 3% up to 10% of the entire tested surface
- the rusted surface is greater than 10% up to 16% of the entire tested surface
- the rusted surface is greater than 16% up to 33% of the entire tested surface
- the rusted surface is greater than 33% up to 50% of the entire tested surface
- the rusted surface is greater than 50% up to 100% of the entire tested surface
- the welded part was broken, and the porosity (%) was measured according to the following equation. In such event, when the porosity is 5% or less, it is indicated as O. When the porosity is 5% or more, it is indicated as X. The 5 samples are evaluated. If all 5 samples were evaluated as O, it was indicated as O. If all 5 samples were evaluated as X, it was indicated as X. If some were evaluated as O and some were evaluated as X, it was indicated as ⁇ .
- Porosity (%) total pore area (mm 2 ) / total welded area (mm 2 )
- the precipitate is a soft cake, it is indicated as O. If it is a hard cake, it is indicated as X. If between O and X, it is indicated as ⁇ .
- Examples 1 to 26 showed excellent results in the evaluation of anti-corrosivity, weldability, zinc salts, and precipitation during storage, whereas Comparative Examples 1, 2, and 5 showed significantly inferior results in the evaluation of corrosivity, and Comparative Examples 3 and 4 showed inferior results in the evaluation of weldability, zinc salts, and precipitation during storage.
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Abstract
The present invention relates to an anti-corrosive coating composition having improved weldability and anti-corrosivity, and an anti-corrosive layer formed from the same. The anti-corrosive coating composition comprises a first liquid and a second liquid, wherein the first liquid comprises an alkyl silicate resin, the second liquid comprises a zinc powder and aluminum tripolyphosphate, and the content of the zinc powder is in a range of 18 to 40% by weight based on the total weight of the anti-corrosive coating composition.
Description
The present invention relates to an anti-corrosive coating composition having improved weldability and anti-corrosivity, and an anti-corrosive layer formed from the same.
An anti-corrosive coating composition is generally referred to as a shop primer, a prefabrication primer, or a first anti-corrosive primer. Such an anti-corrosive coating composition is used to coat steel, which is a base material of a steel structure, to prevent the steel structure from being exposed to the atmosphere and corroding.
Various anti-corrosive paints that contain conventional anti-corrosive pigments have been known. High zinc content paints, which contain a large amount of a zinc powder and a binder, among the above are widely used as temporary anti-corrosive paints for large steel reinforcing structures such as ships, bridges, and the like.
Although the zinc powder contained in the high zinc content paints improves the anti-corrosivity, it increases zinc salts at the same time, which reduces the attachability to an overcoating composition coated thereon. In addition, gases and fumes generated when zinc is vaporized or oxidized during welding increase the generation of such defects as pits and blowholes.
Furthermore, when the high zinc content paint is coated to a thickness of about 15 to 20 ㎛ in order to maintain the physical properties thereof, there is a problem that volatile organic compounds (VOCs) generated from the coated paint are discharged in a large amount of about 48 g/m2 in average per unit area.
In recent years, the need for environmentally friendly paints is gradually increasing, which requires that VOCs emissions from paints should be reduced. Accordingly, a method has been proposed in which the thickness of a coating layer is reduced, whereby the total amount of paint used is lowered and the total VOCs emissions are reduced. However, if the thickness of a coating layer is reduced to lower the amount of VOCs emissions, the content of zinc in the coating layer is also reduced, which causes the problem that the anti-corrosivity is deteriorated.
An object of the present invention is to provide an anti-corrosive coating composition and an anti-corrosive layer formed from the same, which have improved corrosivity and weldability even with the same or a thinner thickness of a coating layer and can reduce VOCs emissions by lowering the total amount of paint used.
The present invention provides an anti-corrosive coating composition, which comprises a first liquid and a second liquid, wherein the first liquid comprises an alkyl silicate resin; the second liquid comprises a zinc powder and aluminum tripolyphosphate; and the content of the zinc powder is in a range of 18 to 40% by weight based on the total weight of the anti-corrosive coating composition.
In addition, the present invention provides an anti-corrosive layer formed from the anti-corrosive coating composition.
The anti-corrosive coating composition according to the present invention has improved anti-corrosivity and weldability even with the same or a thinner thickness of a coating layer.
In addition, the anti-corrosive coating composition according to the present invention can reduce the thickness of a coating layer, whereby the amount of an organic solvent to be used is lowered, and it is environmentally friendly since the VOCs emissions can be reduced.
Hereinafter, the present invention is described in detail. The examples may be modified into various forms as long as the gist of the invention is not altered.
Hereinafter, the present invention will be described more specifically with reference to examples. The following examples are illustrative of the present invention, and the scope of the present invention is not limited thereto.
In this specification, when a part is referred to as "comprising" an element, it is to be understood that the part may comprise other elements as well, unless otherwise indicated.
In addition, all numbers and expression related to the quantities of components, reaction conditions, and the like used herein are to be understood as being modified by the term "about," unless otherwise indicated.
The terms first, second, and the like are used herein to describe various elements, and the elements should not be limited by the terms. The terms are used only for the purpose of distinguishing one element from another.
The present invention provides an anti-corrosive coating composition having improved weldability and anti-corrosivity, and an anti-corrosive layer formed from the same.
The anti-corrosive coating composition according to an embodiment comprises a first liquid and a second liquid.
The anti-corrosive coating composition is a two-part type, anti-corrosive coating composition.
The first liquid comprises an alkyl silicate resin.
The alkyl silicate resin employed in the anti-corrosive coating composition of the present invention serves to directly bond to the zinc powder and steel to enhance attachability and adhesiveness.
The content of the alkyl silicate resin is 10 to 40% by weight based on the total weight of the first liquid. Specifically, the content of the alkyl silicate resin may be 15 to 30% by weight or 20 to 30% by weight based on the total weight of the first liquid, but it is not limited thereto.
The content of the alkyl silicate resin is 5 to 20% by weight based on the total weight of the anti-corrosive coating composition. Specifically, the content of the alkyl silicate resin may be 5 to 15% by weight or 8 to 12% by weight based on the total weight of the anti-corrosive coating composition, but it is not limited thereto.
If the content of the alkyl silicate resin satisfies the above ranges, there is an advantageous effect on the attachability to steel and the anti-corrosivity. Specifically, if the content of the alkyl silicate resin is less than 5% by weight based on the total weight of the anti-corrosive coating composition, the attachability to steel is poor. If the content exceeds 20% by weight, the anti-corrosivity is deteriorated.
The alkyl silicate resin is at least one selected from the group consisting of tetramethoxy silicate, tetraethoxy silicate, tetrapropoxy silicate, tetraisopropoxy silicate, tetrabutoxy silicate, tetramethyl orthosilicate, tetraethyl orthosilicate, tetra-n-propyl orthosilicate, tetraisopropyl orthosilicate, tetra-n-butyl orthosilicate, tetra-sec-butyl orthosilicate, methyl polysilicate, and ethyl polysilicate.
The alkyl silicate resin may be a hydrolysis condensate of an alkyl silicate.
The alkyl silicate resin has a silica content of 20 to 60% by weight. Specifically, the alkyl silicate resin may have a silica content of 25 to 50% by weight or 30 to 40% by weight, but it is not limited thereto.
The alkyl silicate resin has an acidity of 0.01 to 100 ppm. Specifically, the alkyl silicate resin may have an acidity of 0.01 to 20 ppm or 0.1 to 10 ppm, but it is not limited thereto.
The alkyl silicate resin has a viscosity of 2 to 10 cps at 25℃. Specifically, the alkyl silicate resin may have a viscosity of 3 to 8 cps or 4 to 6 cps, but it is not limited thereto.
The alkyl silicate resin has a specific gravity of 0.9 to 1.1. Specifically, the alkyl silicate resin may have a specific gravity of 0.95 to 1.1 or 1.0 to 1.1, but it is not limited thereto.
The first liquid may further comprise a first solvent in addition to the alkyl silicate resin.
The first solvent contained in the anti-corrosive coating composition serves to improve the wettability and workability and to contribute to hydrolysis, thereby controlling the pot life and storability.
Although the first solvent is not particularly limited, specifically, solvents commonly used in the field of coatings such as water, alcohol-based solvents, ester-based solvents, ketone-based solvents, aromatic-based solvents, glycol-based solvents, or the like may be used.
Examples of the alcohol-based solvent include methanol, ethanol, isopropanol, and butanol. Examples of the ester-based solvent include ethyl acetate and butyl acetate. Examples of the ketone-based solvent include methyl isobutyl ketone and cyclohexanone. Examples of the aromatic-based solvent include benzene, xylene, and toluene. Examples of the glycol-based solvent include propylene glycol monomethyl ether and propylene glycol monomethyl ether acetate.
The first solvent may be used alone or in combination of two or more.
The first liquid may further comprise an acid catalyst or an accelerator. In addition, the first liquid may further comprise an acid catalyst and an accelerator.
The acid catalyst and the accelerator are used for expediting the hydrolysis reaction and serve to strengthen the strength at the same time.
An inorganic acid, an organic acid, or the like may be used as the acid catalyst. Examples of the inorganic acid include hydrochloric acid, hydrofluoric acid, hydrobromic acid, hydroiodic acid, sulfuric acid, sulfurous acid, nitric acid, nitrous acid, chloric acid, perchloric acid, and phosphoric acid. Examples of the organic acid include acetic acid, propionic acid, stearic acid, phthalic acid, and salicylic acid. These may be used alone or in combination of two or more.
The acid catalyst is generally somewhat slow and proceeds in a more controlled manner as compared with partial decomposition by a base. In addition, the presence of an acid tends to stabilize the reactive silanol (Si-OH) functional groups and to increase the storage stability.
Zinc chloride, magnesium chloride, dibutyltin laurate, dioctyltin laurate, or the like may be used as the accelerator. The maximum amount of the accelerator to be added is limited by the fast cure that negatively affects the cracking level (or internal stress).
The second liquid comprises a zinc powder and aluminum tripolyphosphate.
The zinc powder contained in the anti-corrosive coating composition serves as an anti-corrosive pigment for preventing the top coat from rusting. Zinc has a higher tendency to ionize than iron, so it has the effect of preventing corrosion of iron as its corrosion occurs in advance in a corrosive environment.
The zinc powder may have various shapes such as a spherical shape, a slightly irregular particle shape, a flake shape, a disk shape, a needle shape, a plate shape, a fiber shape, a rod shape, and the like. For example, the zinc powder may have a spherical shape. In such event, the spherical shape refers to a shape approximate to a sphere. The aspect ratio does not have a specifically defined range, but it is preferably about 1 to 3.
The zinc powder has an average particle diameter of 1 to 20 ㎛. Specifically, the zinc powder has an average particle diameter of 1 to 10 ㎛, 2 to 8 ㎛, or 3 to 6 ㎛, but it is not limited thereto.
Specifically, the content of the zinc powder is in a range of 18 to 40% by weight based on the total weight of the anti-corrosive coating composition. Specifically, the content of the zinc powder may be in a range of 18 to 40% by weight, 19 to 40% by weight, or 19 to 38% by weight, based on the total weight of the anti-corrosive coating composition, but it is not limited thereto.
The content of the zinc powder is in a range of 40 to 70% by weight based on the total weight of the solids content of the anti-corrosive coating composition.
If the content of the zinc powder is in the above ranges, there is an advantageous effect in terms of the anti-corrosivity, attachability, precipitation problem, and the like. Specifically, if the content of the zinc powder is less than 40% by weight based on the total weight of the solids content of the anti-corrosive coating composition, the anti-corrosivity is deteriorated. If it exceeds 70% by weight, zinc salts increase, so that the attachability to an overcoat may be deteriorated and a precipitation problem may occur.
The aluminum tripolyphosphate contained in the anti-corrosive coating composition, together with the zinc powder, produces the effect of significantly enhancing the anti-corrosivity of a coating layer.
The content of the aluminum tripolyphosphate is in a range of 2 to 12% by weight based on the total weight of the anti-corrosive coating composition.
If the content of the aluminum tripolyphosphate is within the above range, it is possible that a thin coating layer having a thickness of 5 to 30 ㎛, specifically 8 to 10 ㎛, may have excellent anti-corrosivity.
The content of P2O5 in the aluminum tripolyphosphate is 30 to 90% by weight. Specifically, the content of P2O5 in the aluminum tripolyphosphate may be 45 to 80% by weight or 50 to 70% by weight, but it is not limited thereto.
The content of Al2O3 in the aluminum tripolyphosphate is 10 to 40% by weight. Specifically, the content of Al2O3 in the aluminum tripolyphosphate may be 15 to 30% by weight or 15 to 20% by weight, but it is not limited thereto.
The aluminum tripolyphosphate may have a specific gravity of 2.5 to 3.5. Specifically, the aluminum tripolyphosphate may have a specific gravity of 2.8 to 3.2 or 2.9 to 3.1, but it is not limited thereto.
The aluminum tripolyphosphate has an oil absorption of 10 to 70 ml/100 g. Specifically, the aluminum tripolyphosphate may have an oil absorption of 35 to 60 ml/100 g or 40 to 50 ml/100 g, but it is not limited thereto.
The second liquid may further comprise an extender pigment.
The extender pigment is intended to maintain the thickness of a coating layer or to increase the mechanical properties thereof. It produces the effect of improving such physical properties of a coating layer as hardness and adjusting the rheology thereof.
The extender pigment is not particularly limited, and a pigment widely used in coating compositions may be generally used. Specifically, it may be at least one selected from the group consisting of calcium carbonate, clay, talc, silica, mica, barium sulfate, potassium feldspar, soda feldspar, calcium feldspar, dolomite, zirconium silicate, zinc oxide, kaolin, wollastonite, and diatomaceous earth, but it is not limited thereto.
The content of the extender pigment is in a range of 0.2 to 15% by weight based on the total weight of the anti-corrosive coating composition.
If the content of the extender pigment is in the above range, there is an advantageous effect of appropriately forming a coating layer and maintaining the hardness thereof.
In addition, the second liquid may further comprise a coloring pigment.
The coloring pigment is intended to impart the necessary color to the anti-corrosive layer to be formed.
The coloring pigment is not particularly limited, and a pigment widely used in coating compositions may be generally used. Specifically, it may be at least one selected from the group consisting of titanium oxide, Bengala, iron oxide, carbon black, copper-chrome-based black pigments, phthalocyanine green, phthalocyanine blue, cobalt blue, organic synthetic pigments, and organic-inorganic synthetic pigments, but it is not limited thereto.
The second liquid may further comprise zinc oxide or zinc phosphate.
The zinc oxide or zinc phosphate contained in the anti-corrosive coating composition, together with the zinc powder and aluminum tripolyphosphate, supplementarily produces the effect of enhancing the anti-corrosivity of a coating layer.
The median diameter (D50) of the zinc oxide or zinc phosphate is 1 ㎛ to 20 ㎛. Specifically, the median diameter (D50) of the zinc oxide or zinc phosphate may be 1 ㎛ to 10 ㎛ or 1 ㎛ to 5 ㎛, but it is not limited thereto.
The zinc oxide or zinc phosphate has a specific gravity of 3.0 to 6.0. Specifically, the zinc oxide or zinc phosphate may have a specific gravity of 5.3 to 5.9 or 3.0 to 3.6, but it is not limited thereto.
The zinc oxide or zinc phosphate has a water content of 0.01 to 3.0% by weight. Specifically, the zinc oxide or zinc phosphate may have a water content of 0.01 to 0.3 % by weight or 1.0 to 3.0% by weight, but it is not limited thereto.
The content of the zinc oxide and zinc phosphate is in a range of 1 to 5% by weight based on the total weight of the anti-corrosive coating composition.
If the content of the zinc oxide and zinc phosphate is in the above range, there is a synergistic effect of further enhancing the anti-corrosivity together with the main anti-corrosive pigment.
The second liquid may further comprise an additive.
The additive is used as a material for improving the performance of a coating or a coating layer or for maintaining it to be constant. Those conventionally used in the coating compositions may be used.
For example, the additive may be a thickener, an anti-settling agent, a drying agent, a flow control agent, a defoaming agent, a dispersant, a color separation inhibitor, a skinning inhibitor, a sagging inhibitor, a plasticizer, an ultraviolet absorbent, or the like. The additive may be used alone or in combination of two or more.
The anti-settling agent may be an organic bentonite type, an oxidized polyethylene type, a fumed silica type, an amide type, or the like, but it is not limited thereto.
The dispersant may be a polyurethane type, a polyacrylic type, a controlled polymerization technology (CPT) type, a fatty acid type, a phosphoric acid ester type, or the like, but it is not limited thereto.
The drying agent may be silica gel, aluminum oxide, zeolite, or the like, but it is not limited thereto.
The ultraviolet absorbent may be a benzophenone type, a benzotriazole type, a salicylic acid type, an acrylonitrile type, an organic nickel compound, a monobenzoic acid type, or the like, but it is not limited thereto.
The second liquid may further comprise a second solvent.
The second solvent contained in the anti-corrosive coating composition serves to improve the wettability and workability and to stabilize the physical properties of the coating and helps disperse the pigment and the like.
Although the second solvent is not particularly limited, specifically, solvents commonly used in the field of coatings such as water, alcohol-based solvents, ester-based solvents, ketone-based solvents, aromatic-based solvents, glycol-based solvents, or the like may be used.
The details on the alcohol-based solvents, ester-based solvents, ketone-based solvents, aromatic-based solvents, glycol-based solvents, and the like are as described above.
The second solvent may be used alone or in combination of two or more.
The second solvent may be the same as, or different from, the first solvent.
The content of the first solvent and the second solvent is 20 to 60% by weight based on the total weight of the anti-corrosive coating composition. Specifically, the content of the first solvent and the second solvent may be 30 to 50% by weight or 40 to 50% by weight based on the total weight of the anti-corrosive coating composition, but it is not limited thereto.
According to an embodiment, the second liquid may further comprise an extender pigment; zinc oxide or zinc phosphate; an additive; and a second solvent.
The first liquid has a viscosity of 8 to 16 seconds at 25℃ as measured by the flow cup method (ASTM D5125). Specifically, the first liquid may have a viscosity of 9 to 11 seconds or 12 to 14 seconds at 25℃, but it is not limited thereto.
The second liquid has a viscosity of 70 to 100 KU at 25℃. Specifically, the second liquid may have a viscosity of 75 to 85 KU or 85 to 95 KU at 25℃, but it is not limited thereto.
If the viscosities of the first liquid and the second liquid are in the above ranges, it is possible to form a coating layer with a small amount of a diluting solvent, thereby reducing VOCs.
The volume ratio of the first liquid to the second liquid is in a range of 65:35 to 50:50. Specifically, the volume ratio of the first liquid to the second liquid may be in a range of 60:40 to 50:50 or 55:45 to 50:50, but it is not limited thereto.
If the volume ratio of the first liquid to the second liquid is in the above range, there is an advantageous effect on the attachability to steel and the anti-corrosivity.
The anti-corrosive coating composition is characterized in that it does not contain a powder that contains Li2O, Na2O, and K2O. If the anti-corrosive coating composition contains a powder that contains Li2O, Na2O, and K2O, pinholes may be generated when a thin coating layer is formed, thereby causing the problem that the anti-corrosivity is deteriorated.
When the degree of rusting is evaluated according to the ASTM D610 evaluation criteria, the degree of rusting of the anti-corrosive coating composition may be 5 or higher. Specifically, the degree of rusting of the anti-corrosive coating composition may be 5 to 10, 6 to 10, 7 to 10, or 8 to 10, but it is not limited thereto.
If the degree of rusting of the anti-corrosive coating composition satisfies the above range, it indicates that the anti-corrosivity is comparatively good as the rusted area is 3% or less of the total area.
Since the anti-corrosive coating composition does not contain an epoxy resin or the like, it falls under an inorganic anti-corrosive coating composition, which is different from organic anti-corrosive coating compositions conventionally used.
Various characteristics of the anti-corrosive coating composition and those of the components of the anti-corrosive coating composition can be combined.
The present invention provides an anti-corrosive layer formed from the anti-corrosive coating composition.
The anti-corrosive layer is formed by the steps of: applying the anti-corrosive coating composition; curing the applied coating composition to form anti-corrosive coating layer; and the like.
In the application step, the anti-corrosive coating composition is applied onto the surface of a substrate such as a steel plate by a conventionally known method such as air spraying, airless spraying, or the like to form an uncured coating layer. Generally, when a coating composition is applied in shipyards or steel mills, an airless sprayer or a line coating machine is mainly used as the application machine. The line coating machine manages the film thickness with the line speed, coating pressure of an air spray, an airless spray, or the like provided in the machine, and spray tip size (i.e., diameter).
In the curing step, the curing temperature (or drying temperature) is usually 5 to 40℃, preferably 10 to 30℃, and the curing time (or drying time) is usually 3 to 15 minutes, specifically 5 to 10 minutes, but they are not limited thereto.
The thickness of the dried anti-corrosive layer is preferably 5 to 15 ㎛. Specifically, the thickness of the anti-corrosive layer is preferably 6 to 15 ㎛, 6 to 12 ㎛, 6 to 10 ㎛, 7 to 15 ㎛, 7 to 12 ㎛, 7 to 10 ㎛, 8 to 15 ㎛, 8 to 12 ㎛, 8 to 10 ㎛, or 8 to 9.5 ㎛.
If the thickness of the anti-corrosive layer is in the above range, it is environmentally friendly since the generation of VOCs is reduced by 10 to 50% as compared with typical anti-corrosive coating compositions. Specifically, if the thickness is less than the above range, it is difficult to form a uniform coating layer and the anti-corrosivity is poor. If it exceeds the above range, the amount of the coating composition to be used increases, which is uneconomical, and the dryness and crack resistance of the coating layer are poor.
The anti-corrosive layer is formed from the anti-corrosive coating composition in which the first liquid and the second liquid having the compositions as described above are mixed, so that it is excellent in denseness and attachability. Thus, it is possible to show excellent anti-corrosivity even if the thickness of a dry film thickness (DFT) is about 5 to 10 ㎛, as well as excellent weldability by virtue of the reduction in coating layer thickness.
Hereinafter, the present invention will be described more specifically with reference to examples. But the following examples are intended to illustrate the present invention, and the scope of the present invention is not limited thereto only.
[Preparation Example] Examples 1 to 26 and Comparative Examples 1 to 5: Preparation of anti-corrosive coating compositions
Tetraethoxysilicate as an alkyl silicate resin and an alcohol solvent, a glycol solvent, and water as a first solvent were mixed, and then a small amount of an acid catalyst and zinc chloride was added thereto, which was stirred for 90 minutes to prepare a first liquid.
A spherical zinc powder, aluminum tripolyphosphate, zinc oxide, an extender pigment, an additive, an aromatic type solvent, an alcohol type solvent, and a glycol type solvent as a second solvent were mixed, which was dispersed and stirred for 120 minutes to prepare a second liquid.
The weights of the alkyl silicate resin, the first solvent, the zinc powder, the aluminum tripolyphosphate, the zinc oxide, the extender pigment, the additive, and the second solvent used in Examples 1 to 26 and Comparative Examples 1 to 5 are shown in Tables 1 to 4.
[Evaluation Example]
Evaluation Example 1: Average thickness of a coating layer
The average thickness of a dried coating layer was measured using an Elcometer 456 instrument. The thickness of the coating layer on the tin-plate (a flat plate for measurement of the thickness of a coating layer) was measured 10 times, and the average value was calculated as the average thickness of the coating layer.
Evaluation Example 2: Evaluation of anti-
corrosivity
A salt spray test was conducted for 30 days according to ASTM B117 in order to measure the anti-corrosivity of the dried layers. The degree of rusting was measured comparatively. Evaluation of the degree of rusting was carried out according to the ASTM D610 evaluation standard described below.
<
ASTM
D610: Evaluation Standard for Rust Generation>
10: The rusted surface is 0.01% or less of the entire tested surface
9: The rusted surface is greater than 0.01% up to 0.03% of the entire tested surface
8: The rusted surface is greater than 0.03% up to 0.1% of the entire tested surface
7: The rusted surface is greater than 0.1% up to 0.3% of the entire tested surface
6: The rusted surface is greater than 0.3% up to 1% of the entire tested surface
5: The rusted surface is greater than 1% up to 3% of the entire tested surface
4: The rusted surface is greater than 3% up to 10% of the entire tested surface
3: The rusted surface is greater than 10% up to 16% of the entire tested surface
2: The rusted surface is greater than 16% up to 33% of the entire tested surface
1: The rusted surface is greater than 33% up to 50% of the entire tested surface
0: The rusted surface is greater than 50% up to 100% of the entire tested surface
Evaluation Example 3: Evaluation of
weldability
Steel specimens of 300 mm × 100 mm × 15T (2 sheets) were prepared and subjected to shot blasting with a thickness of Sa2½ and a roughness of 30 to 75 ㎛. When both sides of the specimen were coated, a tin-plate (a flat plate for measurement of the thickness of a coating layer) was prepared and coated together. Since it is impossible to measure the exact thickness of the coating layer on the specimens due to the roughness, the thickness of the coating layer on the tin-plate was measured ten times, and the average value was taken as the coating layer thickness. After the coated specimens were dried for 7 days, the two specimens were superposed with each other in half, and the 300 mm sides were welded. The welded part was broken, and the porosity (%) was measured according to the following equation. In such event, when the porosity is 5% or less, it is indicated as O. When the porosity is 5% or more, it is indicated as X. The 5 samples are evaluated. If all 5 samples were evaluated as O, it was indicated as O. If all 5 samples were evaluated as X, it was indicated as X. If some were evaluated as O and some were evaluated as X, it was indicated as △.
Porosity (%) = total pore area (mm2) / total welded area (mm2)
Evaluation Example 4: Evaluation of zinc salts
After a uniform anti-corrosive layer is formed by air spray or airless spray, 1 ml of water was dropped on the anti-corrosive layer daily from day 1 to day 7, and the generation of zinc salts was observed. In such event, when a small amount of zinc salts was generated, it is indicated as O. When an excessive amount of zinc salts was generated, it is indicated as X. If between O and X, it is indicated as △.
Evaluation Example 5: Evaluation of precipitation during storage
0.8 liter of the second liquid was placed in a container, sealed, and placed in a chamber whose temperature was maintained at 40℃. After 1 month, the precipitation thereof was evaluated. Whether the precipitate was a soft cake or a hard cake was evaluated. If the precipitate is hard, it cannot be used for coating purposes.
- Soft cake: when the precipitate was agitated by a bar, it became loose
- Hard cake: when the precipitate was agitated by a bar, it did not become loose well
Here, if the precipitate is a soft cake, it is indicated as O. If it is a hard cake, it is indicated as X. If between O and X, it is indicated as △.
[Table 1]
[Table 2]
[Table 3]
[Table 4]
[Table 5]
Examples 1 to 26 showed excellent results in the evaluation of anti-corrosivity, weldability, zinc salts, and precipitation during storage, whereas Comparative Examples 1, 2, and 5 showed significantly inferior results in the evaluation of corrosivity, and Comparative Examples 3 and 4 showed inferior results in the evaluation of weldability, zinc salts, and precipitation during storage.
Claims (15)
- An anti-corrosive coating composition, which comprises a first liquid and a second liquid,wherein the first liquid comprises an alkyl silicate resin;the second liquid comprises a zinc powder and aluminum tripolyphosphate; andthe content of the zinc powder is in a range of 18 to 40% by weight based on the total weight of the anti-corrosive coating composition.
- The anti-corrosive coating composition of claim 1,wherein the content of the aluminum tripolyphosphate is in a range of 2 to 12% by weight based on the total weight of the anti-corrosive coating composition.
- The anti-corrosive coating composition of claim 1,wherein the second liquid further comprises an extender pigment.
- The anti-corrosive coating composition of claim 3,wherein the content of the extender pigment is in a range of 0.2 to 15% by weight based on the total weight of the anti-corrosive coating composition.
- The anti-corrosive coating composition of claim 1,wherein the second liquid further comprises zinc oxide or zinc phosphate.
- The anti-corrosive coating composition of claim 5,wherein the content of the zinc oxide and zinc phosphate is in a range of 1 to 5% by weight based on the total weight of the anti-corrosive coating composition.
- The anti-corrosive coating composition of claim 1,wherein the content of the zinc powder is in a range of 40 to 70% by weight based on the total weight of the solids content of the anti-corrosive coating composition.
- The anti-corrosive coating composition of claim 1,wherein the alkyl silicate resin comprises at least one selected from the group consisting of tetramethoxy silicate, tetraethoxy silicate, tetrapropoxy silicate, tetraisopropoxy silicate, tetrabutoxy silicate, tetramethyl orthosilicate, tetraethyl orthosilicate, tetra-n-propyl orthosilicate, tetraisopropyl orthosilicate, tetra-n-butyl orthosilicate, tetra-sec-butyl orthosilicate, methyl polysilicate, and ethyl polysilicate.
- The anti-corrosive coating composition of claim 1,wherein the alkyl silicate resin has a specific gravity of 0.9 to 1.1.
- The anti-corrosive coating composition of claim 1,wherein the zinc powder has an average particle diameter of 1 to 20 ㎛.
- The anti-corrosive coating composition of claim 1,wherein the first liquid further comprises a first solvent.
- The anti-corrosive coating composition of claim 1,wherein the second liquid further comprises an extender pigment; zinc oxide or zinc phosphate; an additive; and a second solvent.
- The anti-corrosive coating composition of claim 1,wherein the volume ratio of the first liquid to the second liquid is in a range of 65:35 to 50:50.
- An anti-corrosive layer formed from the anti-corrosive coating composition of claim 1.
- The anti-corrosive layer of claim 14,which has a thickness of 5 to 15 ㎛.
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| CN114891423A (en) * | 2022-03-10 | 2022-08-12 | 北京东方雨虹防水技术股份有限公司 | Workshop primer and preparation method thereof |
| EP3845608B1 (en) * | 2018-08-31 | 2024-09-18 | Chugoku Marine Paints, Ltd. | Rust preventive coating composition and use of same |
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| KR102783824B1 (en) * | 2022-06-22 | 2025-03-21 | 주식회사 케이씨씨 | Inorganic coat composition |
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|---|---|---|---|---|
| JP2000309748A (en) * | 1999-04-26 | 2000-11-07 | Chugoku Marine Paints Ltd | Heat-resistant coating composition for steel, coating film, large-sized steel structure covered with the coating film, and method for coating steel structure |
| JP2008156377A (en) * | 2006-12-20 | 2008-07-10 | Sumitomo Metal Ind Ltd | Laser cutting steel and coating composition therefor |
| WO2012036210A1 (en) * | 2010-09-14 | 2012-03-22 | 中国塗料株式会社 | Aqueous coating composition and corrosion prevention method using said aqueous coating composition |
| KR20150013907A (en) * | 2012-07-20 | 2015-02-05 | 주고꾸 도료 가부시키가이샤 | Primary rust preventive coating composition and use thereof |
| KR20170041868A (en) * | 2014-09-26 | 2017-04-17 | 주고꾸 도료 가부시키가이샤 | Rust-inhibiting paint composition and application for same |
-
2018
- 2018-06-22 KR KR1020180071983A patent/KR20200000101A/en not_active Ceased
-
2019
- 2019-06-21 WO PCT/KR2019/007512 patent/WO2019245326A1/en active Application Filing
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000309748A (en) * | 1999-04-26 | 2000-11-07 | Chugoku Marine Paints Ltd | Heat-resistant coating composition for steel, coating film, large-sized steel structure covered with the coating film, and method for coating steel structure |
| JP2008156377A (en) * | 2006-12-20 | 2008-07-10 | Sumitomo Metal Ind Ltd | Laser cutting steel and coating composition therefor |
| WO2012036210A1 (en) * | 2010-09-14 | 2012-03-22 | 中国塗料株式会社 | Aqueous coating composition and corrosion prevention method using said aqueous coating composition |
| KR20150013907A (en) * | 2012-07-20 | 2015-02-05 | 주고꾸 도료 가부시키가이샤 | Primary rust preventive coating composition and use thereof |
| KR20170041868A (en) * | 2014-09-26 | 2017-04-17 | 주고꾸 도료 가부시키가이샤 | Rust-inhibiting paint composition and application for same |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3845608B1 (en) * | 2018-08-31 | 2024-09-18 | Chugoku Marine Paints, Ltd. | Rust preventive coating composition and use of same |
| CN114891423A (en) * | 2022-03-10 | 2022-08-12 | 北京东方雨虹防水技术股份有限公司 | Workshop primer and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| KR20200000101A (en) | 2020-01-02 |
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