Rust inhibitor
A rust inhibitor which ensures the simplicity of application typical for a coating process and can demonstrate excellent characteristics similar to those obtained with a metal spraying method. The rust inhibitor is manufactured by admixing zinc and aluminum as fine powders of inorganic metals, which are manufactured with a stamping mill to have a flaky shape, to a modified silicone resin solution. A silane-type silicone resin is used for the modified silicone resin solution. For example, a mixed solution of an organosilane-type silicone resin and an oligomer-type silane coupling agent and the like is used.
1. A method of inhibiting the formation of rust comprising:
preparing zinc flakes of a size ranging from 150 mesh up to 300 mesh and aluminum flakes of the same mesh range;
preparing a rust inhibitor consisting essentially of the zinc flakes, the aluminum flakes, and a modified silicone resin solution;
coating an iron or steel structure with the rust inhibitor; and
drying the coated rust inhibitor.
2. A rust inhibitor consisting essentially of:
zinc flakes of a size ranging from 150 mesh up to 300 mesh;
aluminum flakes of a size ranging from 150 mesh up to 300 mesh; and
a solution of modified silicone resin.
3. A rust inhibitor according to claim 2 , wherein the zinc flakes and the aluminum flakes are manufactured from zinc powder and aluminum powder, respectively, with a stamping mill.
4. A rust inhibitor according to claim 2 , wherein the modified silicone resin has two types of functional groups with different reactivity.
5. A rust inhibitor according to claim 2 , wherein the modified silicone resin solution comprises an organosilane-type silicone resin.
6. A rust inhibitor according to claim 2 , wherein the modified silicone resin solution comprises an alkoxy oligomer having an alkoxysilyl group (Si—OR).
7. A rust inhibitor according to claim 2 , wherein the modified silicone resin solution comprises a demethanolization-curable methyl-type silicone resin.
8. A rust inhibitor according to claim 2 , wherein the modified silicone resin solution comprises an oligomer-type silane coupling agent.
9. A rust inhibitor according to claim 2 , wherein the modified silicone resin solution further comprises a curing catalyst.
10. A rust inhibitor according to claim 2 , wherein the modified silicone resin solution further comprises an aluminum alkoxide (Al(OR) 3 ).
11. A rust inhibitor according to claim 10 , wherein the modified silicone resin solution further comprises at least one alcohol.
12. A rust inhibitor according to claim 2 , wherein the viscosity of the modified silicone resin solution is 22-25 mm 2 /S at a temperature of 25° C.
13. A rust inhibitor according to claim 2 , wherein the zinc flakes and the aluminum flakes are of a size ranging from 150 to 180 mesh.
14. A method for producing a rust inhibitor comprising:
preparing zinc flakes of a size ranging from 150 mesh up to 300 mesh and aluminum flakes of a size ranging from 150 mesh up to 300 mesh from zinc powder and aluminum powder, respectively, using a stamping mill;
mixing the zinc flakes and the aluminum flakes with a solution of modified silicone resin,
wherein the rust inhibitor consists essentially of the zinc flakes, the aluminum flakes, and the modified silicone resin solution.