ANTI-CORROSION COATINGS
The present invention is directed to anti-corrosion coatings. It is particularly directed to coatings comprising a monomer, such as pyrrole, aniline, thiophene, or their analogs, and a resin. These coatings can be used with substrates such as cold-rolled steel and other metals to inhibit surface oxidation.
1 . A process for producing an anti-corrosion resin, said process comprising the steps of:
A1) reacting a mixture comprising:
(a) a monomer selected from the group consisting of pyrrole, substituted pyrrole, aniline, substituted aniline, thiophene, substituted thiophene, and a combination thereof;
(b) a primer comprising a resin selected from the group consisting of acrylic, polyester, epoxy, melamin/formaldehyde, polyurethane resins, and a combination thereof;
(c) potassium tetraoxalate; and
(d) ammonium persulfate to form a modified resin.
2 . The process of claim 1 , wherein said reaction is conducted in the presence of a metal substrate.
3 . The process of claim 1 further comprising the steps of:
A2) isolating the modified resin from the mixture to form an isolated modified resin.
4 . The process of claim 3 further comprising the steps of:
A3) dissolving the isolated modified resin in one or more solvents to form a modified resin solution.
5 . The process of claim 4 , wherein the one or more solvents comprise methy isobutyl ketone (MIBK).
6 . An anti-corrosion resin produced by the a process comprising the steps of:
A1) reacting a mixture comprising:
(a) a monomer selected from the group consisting of pyrrole, substituted pyrrole, aniline, substituted aniline, thiophene, substituted thiophene, and a combination thereof;
(b) a primer comprising a resin selected from the group consisting of acrylic, polyester, epoxy, melamin/formaldehyde, polyurethane resins, and a combination thereof;
(c) potassium tetraoxalate; and
(d) ammonium persulfate.
7 . A coating composition comprising:
one or more solvents; and
an anti-corrosion resin produced by a process comprising the steps of:
A1) reacting a mixture comprising:
(a) a monomer selected from the group consisting of pyrrole, substituted pyrrole, aniline, substituted aniline, thiophene, substituted thiophene, and a combination thereof;
(b) a primer comprising a resin selected from the group consisting of acrylic, polyester, epoxy, melamin/formaldehyde, polyurethane resins, and a combination thereof;
(c) potassium tetraoxalate; and
(d) ammonium persulfate.
8 . A coated article comprising a metal substrate and one or more coating layers, wherein at least one of the coating layers is formed from an anti-corrosion resin produced by a process comprising the steps of:
A1) reacting a mixture comprising:
(a) a monomer selected from the group consisting of pyrrole, substituted pyrrole, aniline, substituted aniline, thiophene, substituted thiophene, and a combination thereof;
(b) a primer comprising a resin selected from the group consisting of acrylic, polyester, epoxy, melamin/formaldehyde, polyurethane resins, and a combination thereof;
(c) potassium tetraoxalate; and
(d) ammonium persulfatethe anti corrosion resin of claim 6 .
9 . The coated article of claim 8 , wherein said coated article is a vehicle, vehicle part, tank, rail, building, appliance or appliance part.
10 . The coated article of claim 8 , wherein said metal substrate comprises one or more metals selected from steel, aluminum, copper, iron, alloys, or a combination thereof.
11 . A coating process for producing an anti-corrosion coating layer over a metal substrate, said process comprising the steps of:
B1) applying an anti-corrosion resin over said metal substrate to form a wet coating layer thereon, wherein said anti-corrosion resin comprises a modified resin formed by reacting a mixture comprising:
(a) a monomer selected from the group consisting of pyrrole, substituted pyrrole, aniline, substituted aniline, thiophene, substituted thiophene, and a combination thereof;
(b) a primer comprising a resin selected from the group consisting of acrylic, polyester, epoxy, melamin/formaldehyde, polyurethane resins, and a combination thereof;
(c) potassium tetraoxalate; and
(d) ammonium persulfate.
12 . The coating process of claim 11 further comprising the step of:
B2) curing said wet coating layer at an ambient temperature in a range of from about 18° C. to about 35° C., at an elevated temperature in a range of from about 35° C. to about 250° C., or a combination thereof, to form said anti-corrosion coating layer over said metal substrate.
13 . The coating process of claim 11 , wherein said anti-corrosion resin is formed in the presence of said metal substrate forming said wet coating layer thereon.
14 . The coating process of claim 11 , wherein said anti-corrosion resin is formed in the absence of said metal substrate and subsequently applied over said metal substrate forming said wet coating layer thereon.
15 . The coating process of claim 14 , wherein said anti-corrosion resin is formed by a resin producing process comprising the steps of:
B1a) reacting said mixture in the absence of said metal substrate to form a modified resin;
B1b) isolating said modified resin from the mixture to form an isolated modified resin; and
B1c) mixing said isolated modified resin with one or more solvents to form said anti-corrosion resin.
16 . The coating process of claim 15 , wherein the one or more solvents comprise methy isobutyl ketone (MIBK).
17 . The coating process of claim 11 , wherein said metal substrate comprises one or more metals selected from steel, aluminum, copper, iron, alloys, or a combination thereof.
18 . The coating process of claim 11 , wherein said metal substrate is cold rolled steel (CRS) free from Zn pre-coating.
19 . The coating process of claim 11 , wherein said anti-corrosion resin is applied over said metal substrate by electro-coating, spray coating, drawdown coating, roller coating, dipping, soaking, brushing, or a combination thereof
20 . A coated article produced by a coating process comprising the steps of:
applying an anti-corrosion resin over said article to form a wet coating layer thereon, wherein said anti-corrosion resin comprises a modified resin formed by reacting a mixture comprising:
(a) a monomer selected from the group consisting of pyrrole, substituted pyrrole, aniline, substituted aniline, thiophene, substituted thiophene, and a combination thereof
(b) a primer comprising a resin selected from the group consisting of acrylic, polyester, epoxy, melamin/formaldehyde, polyurethane resins, and a combination thereof
(c) potassium tetraoxalate; and
(d) ammonium persulfate.
21 . The coated article of claim 20 , wherein said coated article is a vehicle, vehicle part, tank, rail, building, appliance or appliance part.