WO2010056147A1 - “basalite stone resin” anticorrosion protective coating - Google Patents

Abstract

The invention relates to the production of a durable polymeric coating resistant to aggressive media on structural elements of buildings and of metal and concrete structures, the anticorrosion protection of structural elements of pipelines, the anticorrosion protection of metallic components and assemblies in various sectors of technology, the installation of durable anticorrosion pourable floors resistant to solvents and petroleum products, and the decorative finishing of the aforementioned protected surfaces.  The polymeric composition belongs to the class of two-pack compositions and is obtained by mixing (immediately before application of the coating) a component A containing an epoxy 4,4’-isopropylidenediphenol resin, an epoxy aliphatic resin and flaked basalt with a flake thickness of 1-2 μm and an area thereof of 0.001-0.02 mm², and a component B containing a mixture of a hardener and the aforementioned flaked basalt.  The obtained coating has good barrier properties, preventing contact of an aggressive corrosive medium with the protected surfaces, and also exhibits a good abrasion and wear resistance.

Description

 Anticorrosive sheeting “BASALIT Stone Resin”

Description of the invention

Purpose of the invention

The invention relates to chemical technology and specifically relates to the creation of anticorrosive polymer barrier coatings on various surfaces, intended for the construction of wear-resistant, thixotropic coatings with increased resistance to aggressive environments and can be used to protect structural elements from metal, concrete, pipelines, buildings and structures, metal assemblies and assemblies in various industries, when creating wear-resistant anti-corrosion bulk floors resistant to solvents and petroleum products, as well as in the decorative finishing of various surfaces.

Prior art and background of the invention.

Currently, coatings designed to protect metal and products from it, such as pipelines, various metal components and assemblies, operating in various conditions, including when exposed to various aggressive environments, have increased requirements. The same increased requirements apply to coatings designed to protect concrete during the construction and decoration of various buildings and structures, in particular when installing bulk floors.

Such increased requirements include increased resistance of coatings to atmospheric influences of various climatic environments, resistance to solvents and oil products, wear resistance of coatings, increased environmental and safety requirements, both when creating them and during their operation. Providing coatings with such properties makes it possible to increase their durability, and hence the increased safety of products and materials in which such protective coatings of a barrier type are used.

First of all, various anti-corrosion, wear-resistant, highly filled coatings meet these requirements, therefore, the creation and selection of filler for such coatings is still an urgent task.

No less important is the choice of a bonding base for such coatings, as well as the choice of a combination of the filler used for these purposes and a bonding base that meets these increased requirements.

So, the well-known polymer anticorrosive coatings that satisfy these requirements are traditionally filled and, in particular, are highly filled.

The most commonly used fillers for these purposes are such fillers as: quartz sand (RU 2250946, 04/27/2005), full quartz microspheres (RU 2004113553? 10/20/2005), various aluminosilicates (andesites, bentonites, perlites, vermiculites, metal oxides (RU 2265619, 12/10/2005), talc, graphite (RU 2264428, 20.1 1.2005). Thus, fillers are used, both plate-shaped and spherical, finely divided with a developed surface.

Of the polymers for these purposes, epoxy resins are widely used in view of their good adhesion to various surfaces and chemical resistance to aggressive environments.

Recently, basalt filler is widely used in such compositions for protective coatings.

The basalt filler is known from the prior art both in the form of basalt flour (SU 443047, 09/15/1974), and in the form of basalt fibers (SU 2260022, 09/10/2005; SU 827511, 05/21/1979)

A polymer composition for a protective coating is known from RU 2067602, 10.10.1996, which will contain an unsaturated polyester maleate resin - May 100. including the interaction product of allyl alcohol with toluene diisocyanate - May 2.15-19.5. hours, polyisocyanate - 6.65-76.5 may. hours, block copolymer-polyorganosiloxane and polyoxyalkylene - from 0.1 to 3.0 May. hours, fluorinated alcohol - 0.5-10.0 may. hours, the polymerization initiator is 0.1 to 8.0 may. o'clock, basalt scales, modified 2% by weight of the scales with a 0.5-1.5% solution in ethyl acetate of the product of the interaction of allyl alcohol with toluene diisocyanate. one.

From SU 1831871, 05/27/1995, a chemically resistant polymer composition for coatings based on acrylate monomers in combination with polyisocyanate, divinylbenzene and containing basalt scale as a filler is known. However, these compositions are quite toxic due to the presence of a large number of solvents, as well as isocyanate-containing components.

The use of basalt filler in the form of basalt flakes can increase the protective properties of coatings, however, as mentioned above, the choice of film-forming is of great importance when creating such protective coatings. And for a long time when creating Various epoxy resins are widely used in such anti-corrosion coatings due to good adhesion to various surfaces and chemical resistance to aggressive environments.

From SU 431198, 06/05/1974 there is known an anticorrosive composition containing an epoxy resin, dibutyl phthalate, an acid hardener and an accelerator, for example dimethylaniline, which has increased wear resistance and heat resistance of the composition under conditions of hydroabrasive wear and contains highly dispersed silicon dioxide with a specific surface area of 150-400 m ² / g both the mineral filler and the components are taken in the following ratio (in parts by weight):

• Epoxy Dianova resin 100

• Dibutyl phthalate 10-20

• Fine silica 1.5-3

• Acid hardener 30-50

• Mineral filler 100 - 500 Accelerator, for example dimethylaniline 0.1-0.5

Moreover, as a hardener, the composition contains phthalic and maleic anhydrides, as a mineral filler - diabase flour, basalt flour, andesitic flour, silicon carbide, electrocorundum.

The composition provides the surface to be protected with increased heat resistance and wear resistance under conditions of hydroabrasive wear, but requires hot curing, which is less technologically advanced.

Another epoxy composition is known from SU 443047, 09/15/1974, used to protect concrete surfaces from destruction, for example, surfaces of sewer pipes and is a mixture of epoxy diane resin, anthracene oil, hardeners - polyethylene polyamine and triethanolamine, and a filler, which is used as basalt flour . wear resistance, but has a long curing time of 6 to 18 hours, and is also quite toxic due to the high content of anthracene oil in it.

From RU 2057157, 03/27/1996, an oil-petrol-resistant coating composition is known that includes an ED-20 epoxy-diane resin, furfural, a solution of diethylene triaminomethylphenol in acetone (at a mass ratio of 2: 1), polybenzylpyridinium chloride (MM 420), perchlorovinyl resin, basalt flakes in the following ratio of components, May. hours

• Epoxy-diane resin ED-20 50-95

• 2-Fyraldehyde 10-40

• A solution in acetone (2: 1 ratio) 30:95

• Polybenzylpyridinium + chloride (M.M. 420) 0.02-2.8

• Perchlorovinyl resin 0.03-3.0

• Basalt flakes 5-250

This composition is also quite toxic due to the presence of furylaldehyde, polybenzylpyridinium chloride.

From RU 2306325, 09/20/2007 a composition is known for producing a polymer protective barrier coating on various surfaces, including metal, concrete surfaces, structural elements of pipelines, metal assemblies, assemblies of various industries from exposure to various aggressive environments. The composition includes the following ratio of components in wt.%: 33.5-41.0 epoxy Dianova resin, 2.5-10.0 dibutyl phthalate and / or aliphatic epoxy resin DEG-1, 4.0-6.5 polyethylene polyamine hardener, 42 5-50.0 lamellar filler in the form of andesitic basalt scales with a plate thickness of 0.2 to 7.0 μm and, if necessary, 0-6.0 aerosil and / or 0-17.5 organic solvent. The invention allows to reduce the toxicity of the composition, protective properties, expand its functional purpose.

Typically, an epoxy-based coating composition is two-pack (two-component) since the hardener is stored separately and added to the composition immediately before using such a composition.

FROM SU 1 164556, 11/15/1997, a composition for producing an anticorrosive coating based on an epoxy binder is known. This known composition consists of two components A and B. Component A contains an epoxy resin with a mol. weight 190 - 600, epoxy resin with a mol. Mass 600 - 1700, ???? , filler barite and organic solvent. Component B contains an emulsion comprising a polyamine-modified phenolic resin, polyamide. The protective properties of this composition are not high enough, taking into account the requirements for protective coatings.

The technical task of the claimed invention is to obtain coatings with high protective properties, having both high wear-resistant properties and low toxicity.

A brief description of the invention.

So, the technical task of the claimed invention is to reduce the toxicity of the composition, improve its barrier protective properties when coating, increase the abrasion resistance of the coating, reduce the cost by increasing the percentage of cheaper inorganic filler (basalt flakes) than a binder (epoxy resin), and expansion its functional purpose.

The technical problem is achieved in that the polymer including epoxy dianovy resin, hardener, basalt filler, contains andesitic basalt scales as flakes of basalt flakes with a thickness of flakes of 1 2 microns and with a size of 0.001-0.02 mm, aromatic oligoamide type ETAL as a hardener, additionally contains an aliphatic epoxy resin, when this composition is a two-pack and is formed by combining component A, containing in mass%:

• epoxy diane resin 45-55;

• aliphatic epoxy resin 8-14;

• the specified andesitic basalt scales 38-42; and component B, containing in mass%:

• the specified oligoamide hardener 57-63;

• the specified andesitic basalt scales 37-43; with a ratio of component A and component B from 2: 0.3 to 2: 1.5.

Thus, it is possible to increase the content of the plate-like basalt filler in the coating, which increases the protective barrier effect and the abrasion resistance of the material, and also reduces the cost of its manufacture.

The polymer composition according to the invention as an epoxy Dianova resin contains, for example, epoxy Dianova resin ED-20, ED-16, ED-40.

As an epoxy aliphatic resin contains, for example, epoxy aliphatic resin DEG-1, TEG-1.

As a hardener, the polymer composition according to the invention contains ETAL type hardeners manufactured by Epital (Moscow), for example ETAL-45M (aromatic oligoamide); It is non-toxic and designed to cure epoxy resins at temperatures from -7 ° C to 45 ° C in conditions of any humidity. (TU 2257-045-18826195-01). filler in the form of basalt flakes with a thickness of flakes of 1 to 2 μm and a size of flakes of 0.001 to 0.02 mm ² .

The basalt scales used in the claimed invention are obtained from the natural material of the basalt group (from the melt), followed by the formation of solid vitrified laminated particles from the melt and chemical-thermal treatment in an oxidizing gas environment.

Adhesive-basaltic scales, used in particular in the claimed invention, is a mixture of basaltic and andesitic scales in various arbitrary proportions that do not strongly affect their final performance.

DETAILED DESCRIPTION OF THE INVENTION

The polymer composition of the invention is prepared as follows:

1. First, component A is prepared by mixing epoxy resins, in particular ED-20 epoxy dianne resin and aliphatic epoxy resin, in particular DEG-1 grades, then disperse andesitic basalt flakes in them with a plate thickness of 1–2 μm and their sizes 0.001– 0.02 mm ² in a mixture of epoxy resins.

2. Get component B by mixing the hardener ETAL - 45 M with the above andesitic basalt scales.

The specific examples of the compositions of the invention given in the following table only illustrate the invention, but do not limit it.

By varying the content of the components of the composition claimed as an invention claimed as an invention, the rheological properties of the composition, as well as the functional purpose of the coating, are changed: the composition can be used to obtain a separate protective coating on various surfaces, capable of being applied to vertical surfaces.

Table 1 shows the quantitative ratio of the composition of component A and B.

Table 1 Component A

The ratio between components A and B upon receipt of the composition according to examples 1 to 3 is, respectively:

• In example 1, the ratio between component A and B is 2: 0.3, which is realized by the content in the composition on May 2. h component B;

• In example 2, the ratio between components A and B is 2: 1, which is realized by the content in the composition on May 2. h Component A and May 1. h component B; • In example 3, the ratio between components A and B is 2:15, which is realized by the content in the composition on May 2. h component A and 1.5 may. h component B.

•

Table 2 presents the main characteristics of the obtained components A and B, as components of the claimed two-pack polymer composition.

table 2

Industrial applicability

After mixing the components A and B, the polymer composition according to the invention is used to obtain a protective coating with high barrier protective properties with respect to the effects of various aggressive environments, atmospheric influences, etc.

The application of the protective coating can be done manually or mechanically. For manual application, components A and B are pre-mixed (prepared in advance and stored separately from each other) in ratios from 2: 0.3 to 2: 1.5, when applied using airless spraying machines, mixing Depending on the coating method, type, its viscosity of the composition (working viscosity) is controlled by heating, however, the components cannot be heated above 6O ⁰ C.

The resulting coating provides its purpose - to prevent contact of the environment, causing corrosion, with the surface to be protected due to the barrier structure of the polymer coating and resistance to aggressive environments of the polymer base.

The resulting coating of the BAZALIT barrier type, having such a conditional name, has good adhesion to various surfaces (metal, concrete, etc.), abrasion resistance, mechanical strength, resistance to aggressive environments, water resistance:

Table 3

The data in table 3 on the properties of the composition according to the invention and coatings obtained on its basis are averaged for examples 1 to 3.

The socially useful result of the proposed invention, based on the use of scaly material from a mineral melt such as basalt flakes in combination with epoxy resins, hardener and the ratio between components A and B, is:

- in providing the possibility of extending the life of ships, automobiles, chemical equipment and other objects by applying chemically resistant and mechanically durable coatings on their surface to protect against corrosion and abrasion;

- in providing the possibility of hardening concrete, gypsum boards, roofing materials, polymers and other composite materials in order to increase their service life;

- in providing the possibility of manufacturing heat and vibration resistant non-combustible heat-insulating plates, hardened flake filler, the use of which in objects of shipbuilding, refrigeration, construction and other areas will increase their fire safety;

- in addition to the list of fillers inexpensive, lightweight, chemically resistant, not hygroscopic and effective material.

The composition is resistant to mechanical wear and tear, able to protect the surface on which they are applied from aggressive media, such as solvents, petroleum products, solutions of acids and alkalis, is gas- and waterproof.

All these indicated properties of the composition according to the invention allow its use for the following purposes:

- Facing concrete and steel tanks, tanks, tanks, basins, sumps, drains, dams, dams, tunnels, collectors, etc.

- Replacement or repair of old, low-quality cladding.

- A sheeting for steel tanks and tanks, bunkers and pipes.

- A protective coating for the roof.

- Insulating coating for asbestos, lead paints and other toxic materials.

- A protective coating for decorative objects, such as racks, supports, drains, drains, hatches, volumetric advertising, etc.

- Protection of floors and walls, which may cause liquids that cause corrosion.

- Anti-abrasive film for mining equipment, mills, crushers, for dump trucks and trucks.

- Protection of frozen salt water reservoirs (fishing trawlers).

Claims

 CLAIM A polymer composition for the protective type of barrier coating on various surfaces, including epoxy Dianov resin, plasticizer, hardener, basalt filler, characterized in that it contains andesitic basalt flakes with a thickness of flakes 1 - 2 μm and with a size of 0.001 - 0.02 mm ² , as a hardener an aromatic oligoamide of the ETAL type, as a plasticizer an aliphatic epoxy resin, the composition being two-pack and is formed by combining component A containing in mass%: epoxy resin 45 - 55 aliphatic epoxy resin 8-14 specified andesitic basalt scales 38 - 42 and component B containing in mass%: specified oligoamide hardener 57 - 63 specified andesitic basalt scales 37 - 43 at a ratio component A and component B from 2: 0.3 to 2: 1.5. SUBSTITUTE SHEET (RULE 26)