CROSS REFERENCE TO RELATED APPLICATIONS

(0001] This application claims priority from U.S. Provisional application No. 62/964,491, filed January 22, 2020, titled ZINC-RICH WATERBORNE EPOXY COATING COMPOSITION

AND METHODS, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

(0002) Embodiments of the present disclosure relate generally to anti -corrosive coating compositions, and more particularly to zinc-rich waterborne epoxy coating compositions and methods relating to such compositions.

BACKGROUND

(0003) (inc-rich coatings are applied to the surface of a metal substrate to protect the metal substrate from corrosion. The zinc interacts with the metal substrate in an electrochemical reaction in which the zinc serves as an electron donor to provide cathodic protection of the metal substrate.

To provide a suitable level of cathodic protection however zinc-rich coatings require high levels of zinc particles to achieve the necessary interaction. Because zinc is an expensive material to add to epoxy coatings, a need exists for a coating that requires less zinc to provide a similar or greater be understood, however, by those skilled in the relevant arts, that embodiments of the present invention may be practiced without these specific details. In other instances, known structures and devices are shown and/or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one of ordinary skill in the applicable art to implement the various forms of the invention. It should be appreciated that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. The full scope of the present disclosure is not limited to the examples described below.

[0005] The present disclosure provides a zinc-rich waterborne epoxy coating composition useful to provide anti-corrosion protection to metal substrates. The zinc-rich waterborne epoxy coating composition may be prepared as a mixture of two pre-blended components or of three preblended components. A first component includes a waterborne amine curing agent. A second component includes an epoxy resin. A third component includes zinc dust. The first component may also include one or more of a thixatrope, a defoamer, a pigment, an extender, and a flash rust inhibitor. The second component may also include a diluent. The third component may also include micaceous iron oxide. When combined, the first, second, and third components produce a zinc-rich waterborne epoxy coating that is applied to the surface of a metal substrate to protect the metal substrate from corrosion.

[0006] As described in further detail below, the zinc-rich waterborne epoxy coating composition comprises a waterborne amine curing agent that forms a micro-porous polymer structure within the cured epoxy film. The micro-porosity of the polymer structure improves the interaction among the zinc particles in the dry film, which increases the conductivity of the particles within the coating, increases the cathodic performance of the zinc particles, and increases the overall corrosion protection of the metal substrate. By increasing the contact between zinc particles, the zinc-rich waterborne epoxy composition provides for the use of a lower level of zinc to accomplish the same cathodic protection compared with an equivalent solvent-based organic zinc-rich coating.

[0007] The waterborne amine curing agent may be a water-dilutable polyamine having a plurality of N-H linkages capable of reacting with the epoxy resin to create a micro-porous polymer structure in the cured film. Waterborne amine curing agents that form a porous structure are used when applying an epoxy coating to a concrete substrate. The micro-pores formed by the amine curing agents provide breathability and moisture permeability to the epoxy coating, which prevents blistering, cracking, or separation that may occur when an epoxy coating is applied to a concrete substrate. In one embodiment, the waterborne amine curing agent of the coating composition is selected from commercially-available waterborne amine curing agents formulated for use in an epoxy coating applied to a concrete substrate. [0008] FIGURE 1 illustrates a scanning electron micrograph of the microporous structure of the waterborne system (using EVONIK ANQU AMINE 701) compared with a standard cycloaliphatic amine at 20,000 times magnification.

[0009] The waterborne amine curing agent may comprise one or more of the following, cycloaliphatic amine, aromatic amine, polyether amine, polyamide, aminoamide, adduct or Mannich-based terminated amine, tertiary amine, and the like. According to some embodiments, the waterborne amine curing agent of the composition comprises for example, EVONIK ANQUAMINE 701, ALLNEX, BECKOPOX EH 623, ALLNEX BECKOPOX EH2162, HEXION EPIKURE 8530-W-75, HEXION EPIKURE 8535-W-50, JEFF AMINE T403, and other like waterborne amine-curing agents.

[0010] The epoxy resin may be liquid, solid or semi-solid, or a dispersion in solvent or water comprising, for example, one or more of bisphenol A, bisphenol F, epoxy phenol Novolac, epoxy cresol, and the like. According to embodiments, the epoxy resin comprises EVONIK ANCAREZ AR555, EVONIK ANCAREZ AR 462, and other like epoxy resins.

[0011] The composition may comprise a diluent to decrease the viscosity or increase the solubility of the epoxy resin. The diluent may be either reactive or non-reactive. In one [0012] The composition may include a reactive diluent. The reactive diluent may chemically react with the epoxy resin during cure. The reactive diluent may be an aliphatic, cycloaliphatic, or aromatic epoxy functional compound. The reactive diluent may be either monofunctional or multifunctional, according to embodiments, the reactive diluent comprises one or more of butyl-glycidyl ether, cresyl-glycidyl ether, 1,4 butanediol diglycidyl ether, 1,6 hexanediol diglycidyl ether, C12-C14 monoglycidyl ether, acrylic polymer, acrylic monomer, and the like.

[0013] The composition may further include up to approximately 5% by weight of at least one additive. Although referred to herein as an additive, the term additive may include an antifoam agent and/or an air-release agent, defoamer, dispersing agent, surfactant, catalyst, and/or flow and leveling agent. According to some embodiments, the additive comprises a defoamer or another chemical selected to prevent foam formation, reduce or eliminate foam after it has formed, or remove air from a liquid or solution. In one embodiment, the defoamer suppresses foam formation during activities of the composition manufacture and application process that agitates the mixture in a maimer that introduces air. additives may include, for example, silicone defoamer, nonsilicone defoamer, unsaturated polyamine amides, acidic polyesters, polar acidic esters, t d l b li id f t id t li li id t l lf i id d th [0015] The composition may further include a desired amount of one or more pigments up to approximately 10.0% by weight. In one embodiment, the pigment is selected from one or more of titanium dioxide, carbon black, red iron oxide, yellow iron oxide, phthalo blue/green, mixed metal pigment, aluminum, zinc, and other like pigments.

[0016] The composition may further include a desired amount of at least one extender up to approximately 50% by weight. In one embodiment the extender is selected from one or more of calcium meta-silicate, barium sulfate, mica (alumni potassium silicate), silica-alumina microspheres, magnesium silicate, calcium carbonate, alumina silicate, glass microspheres, hollow micro-spheres, nephelline syenite, micaceous iron oxide, silica, pyrophillite, zinc, and the like.

[0017] The composition may further include a flash rust inhibitor up to 5% by weight. The flash rust inhibitor stops corrosion formation that may occur during the drying process of the zinc- rich waterborne epoxy coating applied to an iron, steel, or other ferrous metal. A flash rust inhibitor may include, for example, sodium nitrite, fatty acid amine complex, and other like flash rust inhibitors.

[0018] The composition may further include a conductive additive that further increases the conductivity of the cured film. According to embodiments, suitable conductive additives may

TABLE 1

[0020] TABLE 1 comprises ranges of weight percentages for the various constituents of a coating composition, in accordance with a first embodiment. For each range disclosed, it is contemplated that each point within the disclosed range is a viable percent weight for the constituent associated with that range, and that the disclosure of the ranges in TABLE 1 constitutes disclosure of the individual points falling within the ranges. [0021] As disclosed above, a zinc-rich waterborne epoxy coating composition may be prepared by the mixture of three pre-blended components. A first component includes a waterborne amine curing agent. A second component includes an epoxy resin. A third component includes zinc dust. The first component may also include one or more of a thixatrope, water, a defoamer, a pigment, an extender, and a flash rust inhibitor. The second component may also include a diluent. The third component may also include micaceous iron oxide. When combined, the first, second, and third components produce a zinc-rich waterborne epoxy coating that is applied to the surface of a metal substrate to protect the metal substrate from corrosion.

[0022] Exemplary embodiments of the waterborne epoxy coating composition are divided into three parts, one aqueous, non-aqueous, and dry, for easy storage and transportation. The aqueous part may be referred to herein as “Component 1,” and includes between 5% to 80% by weight curing agent, between 5% to 50% by weight curing agent, or between 15% and 35% curing agent, in a total amount sufficient to react with epoxy resin included in the non-aqueous part, and desired amounts of other additives as described above and in the examples below. The nonaqueous part may be referred to herein as “Component 2,” and includes between 0% to 100% by weight epoxy resin, between 50% to 100% by weight epoxy resin, or between 80% to 100% epoxy resin; and desired amounts of other additives as described above and in the examples below. The dry part is may be referred to herein as “Component 3,” and includes between 40% to 100% by weight zinc dust, between 60% to 100% by weight zinc dust, or between 80% to 100% zinc dust; and desired amounts of other additives as described above and in the examples below.

[0023] Although the zinc-rich waterborne epoxy coating is shown and described as a three - component composition, the constituents of Component 3 and/or the zinc may be mixed into

Component 1, Component 2, or a combination of Component 1 and Component 2, according to particular needs. Although a two component composition would be more easily transported, a three component composition gives better flexibility to adjust the amount of zinc present in the composition. As described in further detail below, the amount of zinc added to the composition may be adjusted depending on the particular environment of the metal substrate that is being coated. Using a three component system provides for the ability to easily increase the amount of zinc in the final product to provide anti-corrosion protection in more corrosive environments as well as easily decrease the amount of zinc in the final product to reduce costs of the coating in less corrosive environments.

[0024] Another embodiment comprises combining the three parts by adding Component 1 to Component 2 in any suitable container with mechanical agitation to substantially uniformly mix the two parts together, wherein the final composition has a stoichiometric ratio of total epoxy groups to equivalent of reactive curing agent amine groups of approximately 0.8:1 to approximately 1.5:1; a ratio of approximately 0.95:1 to 1.25, or a ratio of approximately 1.05:1 to

1.15:1. Component 3 may be added after Component 1 and Component 2 are mixed. The substantially uniformly mixed composition is then applied to the surface to be coated appropriate epoxy coating application equipment. The weight ratios of Component 1 and Component 2 are determined by the stoichiometric ratio, disclosed above. When working with a three component formula the amount of Component 3 to be used is determined by the zinc load desired in the coating.

[0025] An embodiment of the waterborne epoxy coating composition comprises an aqueous Component 1 that includes a waterborne amine curing agent, a thixatrope, a defoamer, a pigment, an extender, and a flash rust inhibitor; a non-aqueous Component 2 that includes an epoxy resin and a reactive diluent; and a solid Component 3 that includes zinc particles and micaceous iron oxide. The three components may be mixed by combining Component 1, Component 2, and Component 3 in a suitable container with mechanical agitation to substantially uniformly mix the three parts together. The substantially uniformly mixed composition may then be applied as a coating to a metal substrate using epoxy coating application equipment, such as, for example, a brush, roller, or airless sprayer. In one embodiment, the composition is applied as a coating with a dry film thickness of between approximately' 0.5 mils to 5.0 mils, in one coat. Although embodiments are described as applying the coating composition with a diy film thickness of approximately 0.5 mils to 5.0 mils in one coat, embodiments contemplate other thicknesses applied in more than one coat, according to particular needs.

[0026] Although the zinc-rich waterborne epoxy coating composition is described above as comprising a particular range of weight percentage for each of the constituents of each component, embodiments contemplate addition of one or more constituents other than those provided in TABLE 1, as well as other ranges of weight percentage for each of the constituents, according to particular needs. It is further contemplated that one of skill in the art will be able to readily ascertain the appropriate amount of the constituent to use based on TABLE 1 , above, as well as the further examples provided below.

TABLE 2

[0027] TABLE 2 comprises ranges of weight percentages for the various constituents of a coating composition, in accordance with a second embodiment. The values provided in TABLE 2 may comprise an alternate embodiment to those provided in TABLE 1.

TABLE 3

[0028] TABLE 3 comprises ranges of weight percentages for the various constituents of a coating composition, in accordance with a third embodiment. For each of the ranges disclosed in TABLES 1-3, the ranges are meant to include every individual point falling within the disclosed range.

[0029] By way of example only and not by way of limitation, one or more examples are provided below as illustrations only, as numerous modifications and variations within the scope of the present disclosure would be apparent to one having skill in the art. Unless otherwise noted,

[0030] TABLE 4 comprises weight percentages for the various constituents of a coating composition, in accordance with a fourth embodiment. In one embodiment, the composition of

TABLE 4 is prepared by mixing 1.5 gallons of Component 1, 0.5 gallons of Component 2, and a variable amount of Component 3 to provide the desired level of corrosion resistance, as shown in greater detail below. As discussed above, traditional zinc rich coatings use very high levels of zinc particles to achieve the necessary interaction of the particles to provide the proper level of protection. For the zinc-rich waterborne epoxy coating of the current disclosure, the micro-porosity of the polymer structure improves the interaction among the zinc particles in the cured film, which increases their conductivity as well as their ability to provide cathodic protection and anti- corrosion protection to a metal substrate. By increasing the contact between zinc particles, the zinc-rich waterborne epoxy coating composition requires a lower level of zinc to provide the same cathodic protection compared with an equivalent solvent-based organic zinc -rich coating.

[0031] Experimental Results

[0032] The experiments below illustrate the corrosion resistance and the galvanic action of the zinc -rich waterborne epoxy coating composition.

TABLE 5

[0033] TABLE 5 comprises conductivity of various dry-film epoxy compositions, according to an embodiment. Here, the galvanic action of the zinc-rich waterborne epoxy coating is compared with solvent-based coatings. Solvent-based organic zinc-rich coatings may be formulated with polyurethane, epoxy, phenoxy, phenolic, and other like resin systems. The use of ceramic microspheres combined with a conductive additive, such as, for example, carbon black, graphene, carbon nanotubes, tin antimony oxide, a conductive resin (such as, for example, polyaniline) may be used to lower the zinc load level to maintain proper cathodic protection. However, the formation of a micro-porous network in the disclosed zinc-rich waterborne epoxy coating compares favorably from a galvanic action, which correlates with the corrosion resistance of the coating. [0034] The corrosion resistance of the zinc-rich waterborne epoxy coating composition was further tested using a salt fog test (ASTM B117), a cyclic salt fog/UV test (ASTM D5894), and a controlled condensation test (ASTM D4585). Results are presented as scribe ratings (ASTM D1654), blister ratings (ASTM D714), and rust ratings (ASTM D610).

TABLE 6

[0035] TABLE 6 illustrates the corrosion resistance of the zinc-rich waterborne epoxy coating composition according to the salt fog test with various weight percentages of zinc for a various number of hours, according to an embodiment. For this test, a sample of steel was coated with the zinc-rich waterborne epoxy coating composition (as disclosed in TABLE 4), placed in a controlled corrosive environment for between 500 and 2000 hours, and subsequently scored for its blister rating and rust rating. As disclosed above, loading level of zinc in the zinc -rich waterborne epoxy composition may be adjusted by increasing or decreasing the amount of Component 3, with respect to the dry film weight of the composition of Components 1 and 2. For example, a 55% weight of zinc in dry film is prepared by mixing 1.5 gallons of Component 1 with 0.5 gallons of Component 2 and 19.25 lbs. of Component 3 using the composition disclosed above in TABLE 4. Embodiments contemplate additional compositions prepared at different percentage weights of zinc in dry film by mixing the following weights of zinc with 1.5 gallons of Component 1 and 0.5 gallons of Component 2: 65% - 30.5 lbs.; 75% - 53.4 lbs., and 82% - 93.7 lbs. The salt fog test was run on steel coated with the zinc-rich waterborne epoxy coating composition having various loading levels of zinc and a coating thickness of 2.5 -3.5 mils dry film thickness (dft). The results indicate that corrosion protection equivalent to a zinc -rich organic coating are achieved by the zinc -rich waterborne epoxy coating composition with much a lower zinc content. For example, a typical zinc-rich organic coating uses a zinc loading level range from 82% to 89% by weight in the dry film, but often provides sufficient corrosion protection at the higher end of the range (i.e. 88% to 89%) zinc by weight of the dry film. As seen above, zinc -rich waterborne epoxy coating composition may achieve similar corrosion resistance with zinc levels as low as 55 w/w%. However, long-term protection (at a 10/10 (blister rating/rust rating)) is provided with for as long as 2000 hours with a zinc-loading level of 75%. Other embodiments contemplate providing the anti -corrosion protection for ferrous metals with a coating of the zinc -rich waterborne epoxy composition having a zinc loading level of greater than 65%, between 65% and 75%, more than 75%. between 75% and 82%, at 82%, or greater than 82%, according to particular needs.

TABLE 7

[0036] TABLE 7 illustrates the corrosion resistance of the zinc-rich waterborne epoxy coating composition according to the salt fog test with an exposure of 3500 hours. For this test, a sample of steel was coated with the zinc-rich waterborne epoxy coating composition (comprising the formulation of TABLE 4 and mixed in the following ratio: 1.5 gallons of Component 1 with 0.5 gallons of Component 2 and 57.4 lbs. of Component 3) placed in a controlled corrosive environment for 3500 hours, and subsequently scored for its scribe rating, blister rating, and rust rating. The testing was run in triplicate with a coating thickness of 2.5 to 3.5 mils dft.

[0037] TABLE 8 illustrates the corrosion resistance of the zinc-rich waterborne epoxy coating composition according to the cyclic salt fog/UV test with an exposure of 1680 hours. The cyclic salt fog/UV test more closely mirrors the conditions of painted metals in real-world outdoor applications. Instead of providing a static set of corrosive conditions, this test provides a more realistic simulation of the compounding effects of changing environmental conditions, such as, for example, corrosive atmospheres, rain, condensed dew, UV light, wet/dry cycling, and temperature cycling. The testing was run in triplicate with a coating thickness of 2.7 to 3.9 mils dft, using a coating composition comprising the formulation of TABLE 4 and mixed in the following ratio:

1.5 gallons of Component 1 with 0.5 gallons of Component 2 and 57.4 lbs. of Component 3.

[0038] TABLE 9 illustrates the corrosion resistance of the zinc-rich waterborne epoxy coating composition according to the controlled condensation test with an exposure of 2000 hours.

As disclosed above, water is a significant factor in the corrosion of metal-substrates. This test scored a metal-substrate coated with the zinc-rich waterborne epoxy coating composition

(comprising the formulation of TABLE 4 and mixed in the following ratio: 1.5 gallons of Component 1 with 0.5 gallons of Component 2 and 57.4 lbs. of Component 3) for water-related failure after exposure for a selected time period to water condensation in a test chamber. Particular failures that may be identified include a deficiency in the coating composition, contamination of the substrate, or inadequate surface preparation. The testing was run in triplicate with a coating thickness of 3.5 to 5.0 mils dft.

[0039] Thus, a zinc-rich waterborne epoxy composition is disclosed which utilizes zinc particles and a waterborne amine curing agent to provide protection to a metal substrate against corrosion and other environmental threats. The coating composition provides corrosion resistance equal to organic solvent based and solvent free epoxy coatings.

[0040] While the exemplary embodiments have been shown and described, it will be understood that various changes and modifications to the foregoing embodiments may become apparent to those skilled in the art without departing from the spirit and scope of the present invention. Reference in the foregoing specification to “one embodiment”, “an embodiment”, or

“another embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment.