U.S. patent application number 12/198805 was filed with the patent office on 2008-12-18 for waterborne epoxy coating composition and method.
Invention is credited to Remi BRIAND, J. Alisa Duncan, Yves Floriot, Jennifer S. McGreal.
Application Number | 20080311305 12/198805 |
Document ID | / |
Family ID | 36596936 |
Filed Date | 2008-12-18 |
United States Patent
Application |
20080311305 |
Kind Code |
A1 |
BRIAND; Remi ; et
al. |
December 18, 2008 |
WATERBORNE EPOXY COATING COMPOSITION AND METHOD
Abstract
A waterborne coating composition comprising a waterborne epoxy
coating with hydraulic cement, which is capable of a thin initial
application. The coating composition may be made, stored and
transported as a two-part composition, where each part is a
pourable liquid. The waterborne epoxy composition cures under
normal conditions and adheres to surfaces including masonry,
concrete and metal.
Inventors: |
BRIAND; Remi; (Overland
Park, KS) ; Duncan; J. Alisa; (Parkville, MO)
; Floriot; Yves; (Montreal, CA) ; McGreal;
Jennifer S.; (Kansas City, KS) |
Correspondence
Address: |
SPENCER, FANE, BRITT & BROWNE
1000 WALNUT STREET, SUITE 1400
KANSAS CITY
MO
64106-2140
US
|
Family ID: |
36596936 |
Appl. No.: |
12/198805 |
Filed: |
August 26, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11018644 |
Dec 20, 2004 |
7435449 |
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12198805 |
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Current U.S.
Class: |
427/407.1 ;
427/427.4; 427/428.01; 427/429; 428/334; 428/335; 428/339;
524/6 |
Current CPC
Class: |
Y10T 428/269 20150115;
Y10T 428/263 20150115; Y10T 428/31511 20150401; C04B 2111/00525
20130101; C04B 41/4853 20130101; C09D 163/00 20130101; Y02W 30/92
20150501; Y02W 30/91 20150501; Y10T 428/264 20150115; C04B 41/63
20130101; C04B 41/009 20130101; C04B 2111/00517 20130101; C04B
28/04 20130101; C04B 2111/00482 20130101; C08L 79/02 20130101; Y02W
30/94 20150501; C04B 28/04 20130101; C04B 14/305 20130101; C04B
18/08 20130101; C04B 20/002 20130101; C04B 24/2641 20130101; C04B
24/281 20130101; C04B 24/42 20130101; C04B 40/065 20130101; C04B
2103/32 20130101; C04B 2103/50 20130101; C04B 2103/61 20130101;
C04B 28/04 20130101; C04B 14/106 20130101; C04B 18/141 20130101;
C04B 18/146 20130101; C04B 20/002 20130101; C04B 24/18 20130101;
C04B 24/2676 20130101; C04B 24/42 20130101; C04B 24/42 20130101;
C04B 40/065 20130101; C04B 2103/54 20130101; C04B 2103/61 20130101;
C04B 41/4853 20130101; C04B 20/004 20130101; C04B 41/4922 20130101;
C04B 41/5079 20130101; C04B 2103/54 20130101; C04B 41/009 20130101;
C04B 28/04 20130101; C04B 41/009 20130101; C04B 28/02 20130101;
C09D 163/00 20130101; C08L 2666/54 20130101 |
Class at
Publication: |
427/407.1 ;
524/6; 428/334; 428/335; 428/339; 427/427.4; 427/428.01;
427/429 |
International
Class: |
B05D 1/36 20060101
B05D001/36; C09D 1/06 20060101 C09D001/06; B32B 5/00 20060101
B32B005/00; B05D 1/02 20060101 B05D001/02; B05D 1/28 20060101
B05D001/28 |
Claims
1. (canceled)
2. A composition for use in coating surfaces with a thin coating,
the composition comprising: (a) a desired amount of at least one
epoxy resin; (b) a desired amount of at least one mono glycidyl
ether reactive diluent; (c) a desired amount of at least one
powdered hydraulic cement; (d) at least one curing agent comprising
a water soluble polyamine composition capable of emulsifying the
epoxy resin; (e) water in an amount at least sufficient to react
with the powdered hydraulic cement; and (f) wherein the composition
forms coatings having a thickness of from approximately 2 mils to
approximately 15 mils.
3. The composition according to claim 2, wherein the epoxy resin is
a liquid epoxy resin comprising approximately 11.0% to 19.0% by
weight of the total composition.
4. The composition according to claim 3, wherein the liquid epoxy
resin is a liquid bisphenol A epoxy resin.
5. The composition according to claim 2, wherein the powdered
hydraulic cement is Portland Cement comprising approximately 30.0%
to 70.0% by weight of the total composition.
6. The composition according to claim 2, wherein the powdered
hydraulic cement is a mixture of approximately 0.50 to 0.95 weight
parts of Portland Cement and approximately 0.05 to 0.50 weight
parts pozzolan powder derived from a group comprising fly ash,
steel slag, silica fume, or calcined kaolin clay.
7. The composition according to claim 2, wherein the curing agent
is a polyamine having a plurality of N--H linkages capable of
reacting with the epoxy resin comprising approximately 8.0% to
18.0% by weight of the total composition.
8. The composition according to claim 2, wherein the curing agent
is a polyoxyalkylene polyamine.
9. The composition according to claim 2, wherein the curing agent
is an arylene polyamine.
10. The composition according to claim 2, wherein the curing agent
is a cyclo-aliphatic polyamine.
11. The composition according to claim 2, wherein the curing agent
comprises a blend of a Mannich base with polyoxyalkylene
polyamines, arylene polyamines, and cyclo-aliphatic polyamines.
12. The composition according to claim 2, wherein the curing agent
comprises a blend of polyoxyalkylene polyamines, arylene
polyamines, and cyclo-aliphatic polyamines.
13. The composition according to claim 2, wherein the composition
further includes approximately 0.1% to 3.3% by weight of a
non-reactive diluent.
14. The composition according to claim 13, wherein the non-reactive
diluent is benzyl alcohol.
15. The composition according to claim 13, wherein the non-reactive
diluent is an aromatic hydrocarbon resin.
16. The composition according to claim 2, wherein the mono glycidyl
ether is present in an amount of approximately 0.8% to 2.6% by
weight of the composition.
17. The composition according to claim 16, wherein the mono
glycidyl ether is a C-6 to C-18 alkyl glycidyl ether.
18. The composition according to claim 16, wherein the mono
glycidyl ether is a C-12 to C-14 alkyl glycidyl ether.
19. The composition according to claim 2, wherein the composition
further includes approximately 6.0% to 24.0% by weight of a
pigment.
20. The composition according to claim 19, wherein the pigment is
titanium dioxide.
21. The composition according to claim 2, wherein the composition
further includes approximately 0.08% to 0.26% by weight of an
organosilicon adhesion promoter.
22. The composition according to claim 21, wherein the
organosilicon adhesion promoter is
.gamma.-glycidoxypropyl-trimethoxy silane.
23. The composition according to claim 2, wherein the composition
further includes approximately 4.0% to 31.0% by weight of a
water-based latex resin.
24. The composition according to claim 23, wherein the water-based
latex resin is a styrene-acrylic latex.
25. The composition according to claim 23, wherein the water-based
latex resin is a styrene butadiene rubber latex.
26. The composition according to claim 23, wherein the water-based
latex resin is an acrylic latex.
27. The composition according to claim 2, wherein the composition
further includes hollow spheres in an amount of approximately 1.0%
to 8.0% by weight of the composition.
28. The composition according to claim 2, wherein the composition
further includes approximately 0.15% to 0.55% by weight of a
non-silicone defoamer.
29. The composition according to claim 2, wherein the composition
further includes approximately 0.15% to 0.55% by weight of a
silicone defoamer.
30. The composition according to claim 2, wherein the composition
further includes approximately 0.01% to 2.4% by weight of a
corrosion inhibitor
31. The composition according to claim 2, wherein the composition
forms coatings having a thickness of from approximately 4 mils to
approximately 12 mils.
32. The composition according to claim 2, wherein the composition
forms coatings having a thickness of from approximately 6 mils to
approximately 10 mils.
33. A paint composition for use in coating surfaces, the
composition comprising: (a) approximately 10% to 42% by weight of
an epoxy resin; (b) approximately 46% to 90% by weight of hydraulic
cement powder; (c) approximately 30% to 60% by weight of a curing
agent comprising a water soluble polyamine composition capable of
emulsifying the epoxy resin; (d) water in an amount at least
sufficient to react with the hydraulic cement; (e) wherein the
volatile organic compound content of the coating composition is not
more than approximately 3.3% by weight of the total composition;
and (f) wherein the coating composition forms coatings having a
thickness of from approximately 2 mils to approximately 15
mils.
34. The composition according to claim 33, wherein the composition
further includes a desired amount of an inert filler.
35. The composition according to claim 34, wherein the inert filler
comprises hollow spheres in an amount of approximately 1.0% to 8.0%
by weight of the total composition.
36. The composition according to claim 33, wherein the composition
is applied to a surface using a brush, roller or airless sprayer to
form a protective coating with a thickness of from approximately 6
mils to approximately 10 mils.
37. The composition according to claim 33, having a gel time of
approximately 60 to 120 minutes.
38. The composition according to claim 33, having approximately 0.8
to 1.3 equivalents of total epoxy groups to 1.0 equivalent of
reactive amine groups.
39. The composition according to claim 33, having approximately 0.2
to 0.9 parts water to 1.0 part of hydraulic cement.
40. A process for protecting a surface, the process comprising: (a)
applying a fluid protective coating composition to the surface, the
coating composition comprising: (i) a desired amount of at least
one epoxy resin; (ii) a desired amount of at least one mono
glycidyl ether reactive diluent; (iii) a desired amount of at least
one powdered hydraulic cement; (iv) at least one curing agent in an
amount sufficient to react with the epoxy resin; and (v) water in
an amount at least sufficient to react with the powdered hydraulic
cement; and (b) permitting the coating composition to cure to form
a protective coating with a thickness of from approximately 2 mils
to approximately 15 mils.
41. The process according to claim 40, wherein the composition is
applied to a surface using a brush, roller or airless sprayer to
form a protective coating with a thickness of from approximately 4
mils to approximately 12 mils.
42. The process according to claim 40, wherein the composition is
applied to a surface using a brush, roller or airless sprayer to
form a protective coating with a thickness of from approximately 6
mils to approximately 10 mils.
43. The process according to claim 40, wherein the composition is
applied in two coats.
44. The process according to claim 40, wherein the composition is
applied in three coats.
45. The process according to claim 40, wherein the composition
further includes: (a) mixing approximately 90 parts epoxy resin
with approximately 10 parts mono glycidyl ether reactive diluent;
(b) adding approximately 1 part hydraulic cement powder to
approximately 0.11 to 1.15 part epoxy mixture; and (c) adding
approximately 1 part hollow spheres to approximately 3 to 50 parts
of hydraulic cement powder to form a first component of said
composition; (d) separately mixing at least one curing agent,
wherein the curing agent is a polyamine having a plurality of N--H
linkages capable of reacting with the epoxy resin, with a desired
amount of latex resin and water to form a second component of said
composition; and (e) combining the first component and the second
component, in a ratio to provide a coating composition having
approximately 0.8 to 1.3 equivalents of total epoxy groups to 1.0
equivalent of reactive amine groups, in a conventional airless
sprayer.
46. The process according to claim 45, wherein the first component
and the second component are combined in a ratio to provide a
coating composition having approximately 0.9 to 1.1 equivalents of
total epoxy groups to 1.0 equivalent of reactive amine groups.
47. The process according to claim 45, wherein the first component
and the second component are combined in a ratio to provide a
coating composition having approximately 0.2 to 0.9 parts water to
1.0 part of hydraulic cement.
48. The process according to claim 45, wherein the first component
and the second component are combined in a ratio to provide a
coating composition having approximately 0.4 to 0.6 parts water to
1.0 part of hydraulic cement.
49. A composition for use in coating surfaces with a thin coating,
the composition comprising: (a) a desired amount of at least one
epoxy resin; (b) a desired amount of at least one powdered
hydraulic cement; (c) a desired amount of at least one type of
hollow spheres; (d) at least one curing agent in an amount
sufficient to react with the epoxy resin; (e) water in an amount at
least sufficient to react with the powdered hydraulic cement; (f)
wherein the composition does not include a separate emulsifier
surfactant; and (g) wherein the composition forms coatings having a
thickness of from approximately 2 mils to approximately 15
mils.
50. A two-component composition for use in coating surfaces, the
composition comprising: (a) a first component including: (i)
approximately 10% to 42% by weight of an epoxy resin; and (ii)
approximately 46% to 90% by weight of hydraulic cement powder; and
(b) a second component including: (i) approximately 30% to 60% by
weight of a curing agent; and (ii) water in an amount at least
sufficient to react with the hydraulic cement; and (c) the first
component and second component being mixed to provide the coating
composition having a gel time of approximately 60 minutes to
approximately 120 minutes, wherein the coating composition forms
coatings having a thickness of from approximately 2 mils to
approximately 15 mils.
51. The composition according to claim 50, wherein the curing agent
includes primary, secondary, and tertiary amine functionality.
52. The composition according to claim 50, wherein the curing agent
is a diamine.
53. A two-component composition for use in coating surfaces, the
composition comprising: (a) an aqueous first component including:
(i) a desired amount of at least one water dispersed epoxy resin;
(ii) a desired amount of at least one latex resin; (iii) a desired
amount of water; and (b) a non-aqueous second component including:
(i) a desired amount of at least one liquid amine curing agent,
wherein the curing agent is a polyamine having a plurality of N--H
linkages capable of reacting with the epoxy resin; (ii) a desired
amount of at least one hydraulic cement powder; (iii) a desired
amount of at least one type of hollow spheres; and (c) the first
component and second component being mixed in a ratio to provide a
coating composition having 0.20 to 0.90 parts water to 1.00 part of
hydraulic cement, wherein the coating composition forms coatings
having a thickness of from approximately 2 mils to approximately 15
mils.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation and claims
priority benefit of an earlier-filed application of the same title,
Ser. No. 11/018,644, filed Dec. 20, 2004. The identified
earlier-filed application is hereby incorporated by reference into
the present application.
FIELD OF THE INVENTION
[0002] This invention relates to coating compositions and, more
particularly, to waterborne epoxy coating compositions and methods
for using such compositions.
BACKGROUND OF THE INVENTION
[0003] Epoxy coating compositions are used to treat surfaces to
protect against corrosion and other forms of wear and tear caused
by use and the environment. The types of surfaces treated include
concrete, metal, and other surfaces. Effective coating compositions
are prized not only for the quality of protection, but also for
easy and efficient transportation, storage, and application. Thus,
a good coating composition will not only protect the surface, but
also be easy to apply and quick to cure.
[0004] The use of epoxy compositions containing volatile organic
solvents has fallen out of favor even though these compositions
provide exceptional anti-corrosion protection. The organic solvent
based compositions are environmentally unfriendly and their use has
been curtailed. Solvent free epoxy coatings often require
sophisticated, non-standard equipment for application.
[0005] Other epoxy coating compositions provide good protection if
applied at the recommended thickness. This recommended thickness
requires multiple coats and each coat must be cured or set before
another coat may be applied. Each additional coat requires
additional labor, which increases the cost of application. Other
coats may be applied at greater initial thickness, but require more
time to set up. Coatings applied at greater initial thicknesses may
also introduce flaws caused by voids from evaporation of volatile
components during the curing process.
[0006] The combination of an epoxy resin and cement in a coating
composition has been used previously to create cement compositions
suitable for overlaying concrete. For example, prior products
include cement based compositions with an epoxy used as "mortars,"
"toppings," or "overlays" to coat Portland cement concrete or metal
surfaces. These compositions use a small portion of epoxy to
enhance the cement composition and the final compositions are thick
like cement and resembles cement. These are generally two-component
compositions having a dry-mix component and a wet-mix component
which are combined to form the final composition for application to
surfaces in thick films, typically greater than about 20 mils.
Other compositions have used an epoxy to bind a cement
composition.
BRIEF SUMMARY OF THE INVENTION
[0007] There is, therefore, provided in the practice of the
invention a novel waterborne fluid coating composition, which is
epoxy based and includes hydraulic cement, for reduced initial
thickness application, and which provides for a quicker application
at a reduced cost. The waterborne epoxy coating composition broadly
includes an epoxy resin, a hydraulic cement powder, a curing agent
and water.
[0008] In one embodiment, the coating composition is prepared by
mixing two pre-blended liquid components; one component containing
a liquid epoxy resin and hydraulic cement powder; and the other
component containing an amine-based curing agent and water. The
first part may also include additives, such as a non-reactive
diluent, a reactive diluent, an organosilicon adhesion promoter, a
pigment, hollow spheres, or other materials. The second part may
also include additives, such as a cement plasticizer, a
non-reactive diluent, a water-based latex resin, a defoamer, a
corrosion inhibitor, or other materials.
[0009] Accordingly, it is an object of the present invention to
provide an improved two-part waterborne epoxy coating providing
anti-corrosion protection.
DETAILED DESCRIPTION
[0010] The waterborne epoxy composition broadly includes an epoxy
resin, cement powder, an amine-based curing agent, and water. The
composition may be enhanced with additives, including a
non-reactive diluent, a reactive diluent, an organosilicon adhesion
promoter, a pigment, hollow spheres, a cement plasticizer, a
water-based latex resin, a defoamer, a corrosion inhibitor, or
other materials Each element of the general formula will be
discussed in detail below, followed by several embodiments of the
composition and the method of production and application.
[0011] In various embodiments of the invention, the epoxy resin is
present in the composition in an amount of about 8.0% to about
23.0% by weight, preferably about 10.0% to about 21.0% by weight,
and more preferably about 11.0% to about 19.0% by weight.
[0012] The epoxy resin may be liquid, solid or semi-solid. The
epoxy resin functions as the curable component of one part of the
two-part epoxy coating composition. In one embodiment, the epoxy
resin may consist of any one of bisphenol A, bisphenol F, epoxy
phenol novolac, epoxy cresol novolac, naphthalene epoxy, or
tertiary butyl cathecol epoxy. Another epoxy may be used besides
those listed here, although these are preferred. In exemplary
embodiments, the epoxy resin is a liquid bisphenol A epoxy resin,
including for example, liquid bisphenol A epoxy resin such as
Huntsman GY6010, or a water-dispersed bisphenol A epoxy resin such
as Resolution EPI-REZ 3510-W-60.
[0013] In various embodiments of the invention, hydraulic cement
powder is present in the composition in an amount of about 20.0% to
about 72.0% by weight, preferably about 28.0% to about 71.0% by
weight, and more preferably about 30.0% to about 70.0% by
weight.
[0014] The hydraulic cement powder may be any type of Portland
cement and may also be any color. Portland cement comes in Types I,
II, III, IV, and V. The possible colors include white, grey, etc.
In another embodiment, the hydraulic cement powder is a mixture of
0.50 to 0.95 weight parts of Portland Cement and 0.05 to 0.50
weight parts pozzolan powder derived from a group comprising fly
ash, steel slag, silica fume, or calcined kaolin clay.
[0015] In various embodiments of the invention, the curing agent is
present in the composition in an amount of about 5.0% to about
21.0% by weight, preferably about 7.0% to about 19.0% by weight,
and more preferably about 8.0% to about 18.0% by weight.
[0016] The curing agent may be a substantially solvent free, or a
water dilutable polyamine having a plurality of N--H linkages
capable of reacting with the epoxy resin. The amine-based curing
agent may be a polyoxyalkylene polyamine, arylene polyamine,
cyclo-aliphatic polyamine, Mannich base, or a blend of two or more
of these polyamines. An example of a solvent free amine curing
agent used in an embodiment is a polyoxypropylene polyamine such as
Huntsman JEFFAMINE D-400. Examples of commercially available
water-based amine curing agents useful in the invention include,
for example, Cognis WATERPOXY 751, UCB BECKOPOX 613, Huntsman
ARADUR 39, Bakelite RUETADUR VE-51, and Air Products ANQUAMINE 287.
Preferably, the curing agent is a water soluble polyamine adduct
containing a grafted internal reactive surfactant on the backbone,
containing primary, secondary and tertiary amine functionality with
some free monomeric polyamine, enabling the emulsification of
liquid epoxy resin, without addition of external surfactant, and
that is miscible with water in all proportions, such as Cognis
WATERPOXY 751, as disclosed in U.S. Pat. No. 6,395,806.
[0017] The coating compositions of the invention are prepared from
a desired amount of epoxy resin such that the weight ratio of epoxy
resin to hydraulic cement is in the range of about 0.1:1 to about
1.2:1; the compositions further provide a ratio of about 0.8 to 1.3
equivalents of total epoxy groups to 1.0 equivalent of reactive
curing agent amine groups; and 0.2 to 0.9 parts water to 1.0 part
hydraulic cement.
[0018] A non-reactive diluent may be added to decrease the
viscosity of the mixture. Any diluent that does not react with the
other elements of the composition and decreases viscosity may be
used. In one embodiment, the non-reactive diluent is benzyl
alcohol, which not only reduces viscosity, but also speeds the
epoxy/amine reaction and helps prevent freezing or crystallization
of the coating composition. In another embodiment, the non-reactive
diluent is an aromatic hydrocarbon resin, such as Rutgers NOVARES
LS 500 for example, which not only reduces viscosity, but also has
lower volatility. The non-reactive diluent may be included in
either or both components of the composition.
[0019] The composition may further include a reactive diluent. The
reactive diluent may be an aliphatic, cycloaliphatic, or aromatic
epoxy functional diluent. The reactive diluent may be either
monofunctional or multifunctional. In one embodiment, the reactive
diluent is a C6 to C18 alkyl mono glycidyl ether, and is included
at a ratio of about 8 to 26 parts per 100 parts of epoxy resin. One
example of a commercial reactive diluent suitable for this
composition is Air Products EPODIL 748.
[0020] The composition may further include an organosilicon
adhesion promoter to enhance the adhesion of the cured composition
to the surface being coated. The organosilicon adhesion promoter is
included in a ratio of about 0.5 to 2 parts to 100 parts of epoxy
resin. In one embodiment, the organosilicon adhesion promoter is
.gamma.-glycidoxypropyl-trimethoxy silane.
[0021] The composition may further include a water-based latex
resin in a ratio of up to about 1.2 parts water-based latex resin
to 1.0 part of hydraulic cement. Examples of useful water-based
latex resins include, acrylic, styrene-acrylic, styrene butadiene
rubber (SBR), polyvinyl acetate (PVA), and ethylene vinyl acetate
(EVA) latexes. In one embodiment, the latex resin is an acrylic,
styrene-acrylic, or styrene butadiene rubber (SBR) latex. Examples
include Rohm & Haas RHOPLEX MC-1834, SYNTHOMER 29Y46 SBR, and
Resolution IC-780.
[0022] The composition may further include a desired amount of
pigment up to about 24.0% in order to achieve the desired coating
color. In one embodiment the pigment is titanium dioxide. The
pigment may be dispersed in either component of the two-part
composition of the invention.
[0023] The composition may further include up to about 8.0%,
preferably about 1.0% to about 8.0%, by weight hollow spheres as an
inert filler. In one embodiment the hollow spheres are hollow
micro-spheres having a particle diameter in the range of about 5 to
90 microns and are included in the hydraulic cement containing
component of the two-part composition in a ratio of about 1 part
hollow spheres to about 3 to 50 parts of hydraulic cement. Examples
include 3M SCOTCHLITE K37 Glass Bubbles and CHL A-90 Hollow Ceramic
Microspheres.
[0024] The composition may further include up to about 0.4% of a
cement plasticizer, such as a lignosulfonate salt, for example
Lignotech Norlig 24C; up to about 0.55% of a defoamer, such as a
non-silicone defoamer, for example BYK-Chemie BYK-011, and/or a
silicone defoamer, for example Tego FOAMEX 805; and up to about
2.4% of a corrosion inhibitor, such as Cortec MCI-2000 or W. R.
Grace DCI S; all as set forth in the following examples and
claims.
[0025] Thus, in various embodiments, the composition of the present
invention includes some or all of the following components: about
0.06% to about 0.40% by weight of a concrete plasticizer; about
0.15% to about 0.55% by weight of a defoamer; and, about 0.01% to
about 2.4% by weight of a corrosion inhibitor.
[0026] One embodiment of the waterborne epoxy coating composition
is divided into two parts for easy storage and transportation. Part
A of this formula is non-aqueous and includes liquid Bisphenol A
epoxy resin, reactive diluent, organosilicon adhesion promoter,
hydraulic cement, and hollow spheres. Part B is aqueous and
includes water-based amine curing agent, water-based latex resin,
and defoamer. The two parts are combined in a sprayer to mix the
two parts together and then apply the coating composition to a
surface, wherein the composition has a weight ratio of epoxy resin
to hydraulic cement in the range of about 0.19:1 to about 0.6:1; a
ratio of about 0.9 to 1.15 equivalents of total epoxy groups to 1.0
equivalent of reactive curing agent amine groups; and 0.3 to 0.6
parts total water to 1.0 part hydraulic cement.
[0027] Another embodiment comprises a non-aqueous Part A including
liquid Bisphenol A epoxy resin, reactive diluent, organosilicon
adhesion promoter, hydraulic cement, and hollow spheres; and an
aqueous Part B including a water-based amine curing agent,
water-based latex resin, and defoamer. The two parts are combined
in a sprayer to mix the two parts together and then apply the
coating composition to a surface, wherein the final composition has
a weight ratio of epoxy resin to hydraulic cement is in the range
of about 0.25:1 to about 0.5:1; a ratio of about 0.95 to 1.1
equivalents of total epoxy groups to 1.0 equivalent of reactive
curing agent amine groups; and 0.4 to 0.6 parts total water to 1.0
part hydraulic cement. Each part is approximately equal in volume
and additional water may be added after the two parts are
mixed.
[0028] Various embodiments of the non-aqueous Part A of the two
part composition of the invention broadly comprise some or all of
the following components: epoxy resin in an amount of about 10% to
about 42% by weight, preferably about 15% to about 33% by weight,
and more preferably about 18% to about 27% by weight of said Part
A; hydraulic cement powder in an amount of about 46% to about 90%
by weight, preferably about 57% to about 84% by weight, and more
preferably about 58% to about 80% by weight of said Part A; hollow
spheres in an amount of about 1% to about 13% by weight of said
Part A; mono glycidyl ether as reactive diluent in an amount of
about 1.1% to about 4.8% by weight of said Part A; and an
organosilicon adhesion promoter in an amount of about 0.1% to about
0.5% by weight, preferably about 0.2% to about 0.4% by weight of
said Part A. Various embodiments of the aqueous Part B of the two
part composition of the invention broadly comprise some or all of
the following components: at least one curing agent, comprising a
water soluble polyamine, in an amount of about 30% to about 60% by
weight, preferably about 34% to about 52% by weight of said Part B;
concrete plasticizer in an amount of about 0.2% to about 0.6% by
weight of said Part B; water-based latex resin in an amount of
about 30% to about 50% by weight of said Part B; defoamer in an
amount of about 0.5% to about 1.0% by weight of said Part B; and
corrosion inhibitor in an amount of about 0.04% to about 18.5% by
weight of said Part B. Further exemplary embodiments are set forth
in the following examples.
[0029] In an alternative embodiment the non-aqueous Part A includes
a solvent-free amine curing agent, hydraulic cement and hollow
spheres. Part B is aqueous and includes a water-dispersed epoxy
resin, and may further contain a water-based latex resin, and
defoamer. The two parts are combined in a sprayer to mix the two
parts together and then apply the coating composition to a surface,
wherein the composition has a weight ratio of epoxy resin to
hydraulic cement in the range of about 0.1:1 to about 1.2:1; a
ratio of about 0.8 to 1.3 equivalents of total epoxy groups to 1.0
equivalent of reactive curing agent amine groups; and 0.2 to 0.9
parts total water to 1.0 part hydraulic cement.
[0030] The embodiments of the waterborne epoxy coating composition
may be applied with a brush, roller, or airless sprayer to produce
cured coatings with a thickness from about 78% to about 95% of the
single coat wet thickness. Exemplary embodiments of the composition
applied by airless sprayer produce cured coatings with a thickness
from about 90% to about 95% of the single coat wet thickness. Said
cured coatings have a thickness of from approximately 2 mils to
approximately 15 mils, preferably having a thickness of
approximately 4 mils to approximately 12 mils, and more preferably
having a thickness of approximately 6 mils to approximately 10
mils. The embodiments of the composition exhibit gel times from
about 60 minutes to about 120 minutes and are dry to touch in less
than 24 hours.
[0031] The embodiments of the composition are more specifically
shown in the following examples, wherein it can be seen that the
embodiments of the composition are prepared without the use of a
separate emulsifier surfactant to stabilize either part of the two
part composition or the final blended composition. It is further
apparent from the foregoing detailed description and the component
ranges from the following examples of embodiments of the
composition of the invention that the composition has low volatile
organic compound content, generally not more than about 3.3% by
weight of the total composition, preferably not more than about
2.2% by weight of the total composition, and more preferably not
more than about 2% by weight of total composition, as indicated by
the non-reactive diluent (benzyl alcohol) content.
TABLE-US-00001 Examples 1 2 3 Weight % Weight % Weight % Part A
Components Epoxy Resin Huntsman GY6010 22.29 20.35 23.26 Reactive
Diluent Air Products Epodil 748 2.50 2.29 2.61 Adhesion Promoter
OSi Silquest A-187 0.25 0.23 0.26 Portland Cement Lehigh Type I
59.43 0 0 Lefarge Fondu Type V 0 66.43 50.32 Pozzolan Lefarge
NewChem Slag 0 0 16.70 Titanium Dioxide Huntsman TR-60 9.60 0 0
Hollow Spheres 2.50 7.59 3.27 Non-reactive Diluent Benzyl Alcohol
3.42 3.12 3.57 Total Part A 100.00 100.00 100.00 Part B Components
Water-based amine curing Cognis Waterpoxy 751 14.95 25.64 51.87
agent Anquamine 287 35.33 10.85 0 Titanium Dioxide Huntsman TR-60
27.82 0 Concrete Super Plasticizer Lignotech Norlig 24C 0.57 0 0
Latex Emulsion Synthomer 29Y46 SBR 48.61 0 0 Rohm & Haas
Rhoplex MC- 0 35.28 0 1834 Non-reactive Diluent Benzyl Alcohol 0.55
0.40 0 Deionized Water 0 0 29.95 Corrosion Inhibitor W. R. Grace
DCI S 0 0 18.18 Total Part B 100.00 100.00 100.00 Examples 4 5 6 7
8 9 10 Weight % Weight % Weight % Weight % Weight % Weight % Weight
% Part A Components Epoxy Resin: 13.04 13.45 12.20 14.44 10.55
16.47 8.23 Huntsman GY6010 Reactive Diluent: Air 1.46 1.51 1.37
1.62 1.19 1.85 0.92 Products Epodil 748 Adhesion Promoter: 0.15
0.15 0.14 0.16 0.12 0.19 0.09 OSi Silquest A-187 Portland Cement:
35.82 37.44 38.90 34.12 43.08 26.68 42.67 Lefarge Secar 71 Type V
Pozzolan: Calcined 7.18 3.74 7.78 2.73 10.77 1.33 21.34 Kaolin
Imerys Metastar 450 Hollow Spheres: 3M 2.34 2.42 2.19 2.60 1.90
2.96 1.48 Scotchlite K37 Non-reactive Diluent: 2.00 2.07 1.87 2.22
1.62 2.53 1.26 Benzyl Alcohol Sub-total 61.99 60.78 64.45
57.9057.89 69.23 52.01 75.99 Part B Components Water-based amine
16.49 17.01 15.42 18.26 13.35 20.82 10.41 curing agent: Cognis
Waterpoxy 751 Deionized Water 4.74 4.90 4.44 5.26 3.84 5.99 3.00
Latex Emulsion: 16.27 16.78 15.22 18.02 13.17 20.54 10.27 Rohm
& Haas Rhoplex MC-1834 Non-reactive Diluent: 0.18 0.19 0.17
0.20 0.15 0.23 0.12 Benzyl Alcohol Defoamer: BYK- 0.33 0.34 0.31
0.36 0.26 0.41 0.21 Chemie BYK-011 (non-silicone) Sub-total 38.01
39.22 35.56 42.10 30.77 47.99 24.01 Examples 11 12 13 14 15 16 17
Weight % Weight % Weight % Weight % Weight % Weight % Weight % Part
A Components Epoxy Resin: Huntsman 11.48 13.16 11.74 12.82 10.43
14.86 8.53 GY6010 Reactive Diluent: Air 1.29 1.48 1.32 1.44 1.17
1.67 0.96 Products Epodil 748 Adhesion Promoter: OSi 0.13 0.15 0.13
0.14 0.12 0.17 0.10 Silquest A-187 Portland Cement: 32.41 27.48
31.44 29.65 35.75 20.20 36.52 Lefarge Secar 71 Type V Pozzolan: Fly
Ash 6.71 2.75 6.29 2.37 8.94 1.01 18.26 Hollow Spheres: 3M 4.27
4.90 4.37 4.77 3.88 5.53 3.17 Scotchlite K37 Non-reactive Diluent:
1.76 2.02 1.80 1.97 1.60 2.28 1.31 Benzyl Alcohol Sub-total 58.05
51.93 57.10 53.17 61.89 45.72 68.85 Part B Components Water-based
amine 14.52 16.64 14.85 16.21 13.19 18.79 10.78 curing agent:
Cognis Waterpoxy 751 Deionized Water 1.35 1.55 1.38 1.51 1.23 1.75
1.00 Titanium Dioxide: 11.3 12.95 11.55 12.61 10.26 14.62 8.39
Huntsman TR-60 Latex Emulsion: Rohm 14.33 16.42 14.65 16.00 13.02
18.54 10.64 & Haas Rhoplex MC- 1834 Non-reactive Diluent: 0.16
0.19 0.17 0.18 0.15 0.21 0.12 Benzyl Alcohol Defoamer: BYK- 0.29
0.33 0.29 0.32 0.26 0.37 0.21 Chemie BYK-011 (non- silicone)
Sub-total 41.95 48.07 42.90 46.83 38.11 54.28 31.15 Examples 18 19
20 21 22 23 24 Weight % Weight % Weight % Weight % Weight % Weight
% Weight % Part A Components Epoxy Resin: Huntsman 13.20 13.85
12.62 14.81 10.99 16.76 8.73 GY6010 Reactive Diluent: Air 1.48 1.56
1.42 1.66 1.23 1.88 0.98 Products Epodil 748 Adhesion Promoter: OSi
0.15 0.16 0.14 0.17 0.12 0.19 0.10 Silquest A-187 Portland Cement:
34.91 35.51 37.07 32.24 41.32 25.01 41.05 Lefarge Fondu Type V
Pozzolan: Lefarge 7.00 3.55 7.41 2.58 10.33 1.25 20.53 NewChem Slag
Hollow Spheres: 3M 5.06 5.31 4.83 5.67 4.21 6.42 3.35 Scotchlite
K37 Non-reactive Diluent: 2.03 2.13 1.94 2.27 1.69 2.57 1.34 Benzyl
Alcohol Sub-total 63.83 62.05 65.43 59.41 69.89 54.08 76.07 Part B
Components Water-based amine 16.07 16.86 15.36 18.03 13.38 20.40
10.63 curing agent: Cognis Waterpoxy 751 Deionized Water 3.83 4.02
3.66 4.30 3.19 4.86 2.53 Latex Emulsion: 15.77 16.55 15.08 17.70
13.13 20.02 10.43 Synthomer 29Y46 SBR Non-reactive Diluent: 0.18
0.19 0.17 0.20 0.15 0.23 0.12 Benzyl Alcohol Defoamer: BYK- 0.32
0.33 0.30 0.36 0.27 0.40 0.21 Chemie BYK-011 (non- silicone)
Sub-total 36.17 37.95 34.57 40.59 30.11 45.92 23.93 Examples 25 26
27 28 29 30 31 Weight % Weight % Weight % Weight % Weight % Weight
% Weight % Part A Components Epoxy Resin: Huntsman 11.81 13.16
12.16 13.92 10.80 15.40 8.82 GY6010 Reactive Diluent: Air 1.33 1.48
1.37 1.56 1.21 1.73 0.99 Products Epodil 748 Adhesion Promoter: OSi
0.13 0.15 0.14 0.16 0.12 0.17 0.10 Silquest A-187 Portland Cement:
33.32 29.83 31.59 26.78 35.90 20.33 36.65 Lefarge Secar 71 White
Type V (Calcium Aluminate) Pozzolan: Silica Fume 6.66 2.98 6.32
2.14 8.97 1.02 18.32 Hollow Spheres: 3M 1.81 2.01 1.86 2.13 1.65
2.36 1.35 Scotchlite K37 Non-reactive Diluent: 1.81 2.02 1.87 2.14
1.66 2.37 1.35 Benzyl Alcohol Sub-total 56.87 51.63 55.30 48.83
60.31 43.37 67.58 Part B Components Water-based amine 14.93 17.07
15.77 18.05 14.00 19.98 11.44 curing agent: Cognis Waterpoxy 751
Deionized Water 1.39 0.65 0.61 0.69 0.54 0.77 0.44 Titanium
Dioxide: 11.62 13.28 12.27 14.05 10.90 15.55 8.90 Huntsman TR-60
Latex Emulsion: Rohm 14.73 16.84 15.56 17.81 13.82 19.72 11.29
& Haas Rhoplex MC- 1834 Non-reactive Diluent: 0.17 0.19 0.18
0.20 0.16 0.22 0.13 Benzyl Alcohol Defoamer: BYK-Chemie 0.30 0.34
0.31 0.36 0.28 0.40 0.23 BYK-011 (non-silicone) Sub-total 43.13
48.37 44.70 51.17 39.69 56.63 32.42 Examples 32 33 34 35 36 37 38
Weight % Weight % Weight % Weight % Weight % Weight % Weight % Part
A Components Epoxy Resin: Huntsman 13.23 13.65 12.37 14.66 10.70
16.72 8.43 GY6010 Reactive Diluent: Air 1.49 1.53 1.39 1.65 1.20
1.88 0.95 Products Epodil 748 Adhesion Promoter: OSi 0.15 0.15 0.14
0.16 0.12 0.19 0.09 Silquest A-187 Portland Cement: 35.89 37.53
38.98 34.20 43.16 26.75 42.49 Federal Type I Pozzolan: Calcined
7.20 3.75 7.80 2.74 10.79 1.34 21.25 Kaolin Imerys Metastar 450
Hollow Spheres: 3M 1.93 1.99 1.80 2.13 1.56 2.43 1.23 Scotchlite
K37 Non-reactive Diluent: 2.03 2.10 1.90 2.25 1.64 2.57 1.29 Benzyl
Alcohol Sub-total 61.921 60.70 64.38 57.79 69.18 51.87 75.73 Part B
Components Water-based amine 16.52 17.05 15.45 18.31 13.37 20.88
10.53 curing agent: Cognis Waterpoxy 751 Deionized Water 4.76 4.91
4.45 5.27 3.85 6.01 3.03 Latex Emulsion: Rohm 16.30 16.82 15.25
18.06 13.19 20.60 10.39 & Haas Rhoplex MC- 1834 Non-reactive
Diluent: 0.18 0.19 0.17 0.20 0.15 0.23 0.12 Benzyl Alcohol
Defoamer: BYK- 0.33 0.34 0.31 0.36 0.27 0.41 0.21 Chemie BYK-011
(non- silicone) Sub-total 38.09 39.30 35.62 42.21 30.82 48.13 24.27
Examples 39 40 41 42 43 44 45 Weight % Weight % Weight % Weight %
Weight % Weight % Weight % Part A Components Epoxy Resin: Huntsman
13.07 13.49 12.23 14.49 10.58 16.52 8.33 GY6010 Reactive Diluent:
Air 1.47 1.52 1.37 1.63 1.19 1.86 0.94 Products Epodil 748 Adhesion
Promoter: OSi 0.15 0.15 0.14 0.16 0.12 0.19 0.09 Silquest A-187
Portland Cement: 35.91 37.55 39.00 34.23 43.18 26.77 42.51 Federal
Type I Pozzolan: Lefarge 7.20 3.75 7.80 2.74 10.79 1.34 21.25
NewChem Slag Hollow Spheres: 3M 2.08 2.14 1.94 2.30 1.68 2.63 1.32
Scotchlite K37 Non-reactive Diluent: 2.01 2.07 1.88 2.22 1.62 2.54
1.28 Benzyl Alcohol Sub-total 61.89 60.68 64.36 57.77 69.16 51.83
75.72 Part B Components Water-based amine 16.53 17.06 15.46 18.32
13.37 20.89 10.53 curing agent: Cognis Waterpoxy 751 Deionized
Water 4.76 4.91 4.45 5.27 3.85 6.01 3.03 Latex Emulsion: Rohm 16.31
16.83 15.25 18.07 13.20 20.61 10.39 & Haas Rhoplex MC- 1834
Non-reactive Diluent: 0.18 0.19 0.17 0.20 0.15 0.23 0.12 Benzyl
Alcohol Defoamer: BYK- 0.33 0.34 0.31 0.36 0.27 0.41 0.21 Chemie
BYK-011 (non- silicone) Sub-total 38.11 39.32 35.64 42.23 30.84
48.17 24.28 Examples 46 47 48 49 50 51 52 Weight % Weight % Weight
% Weight % Weight % Weight % Weight % Part A Components Epoxy
Resin: Huntsman 13.11 13.53 12.26 14.53 10.60 16.58 8.34 GY6010
Reactive Diluent: Air 1.47 1.52 1.38 1.63 1.19 1.86 0.94 Products
Epodil 748 Adhesion Promoter: OSi 0.15 0.15 0.14 0.16 0.12 0.19
0.09 Silquest A-187 Portland Cement: 36.02 37.66 39.10 34.33 43.28
26.86 42.58 Federal Type I Pozzolan: Silica Fume 7.22 3.77 7.82
2.75 10.82 1.34 21.29 Hollow Spheres: 3M 1.80 1.86 1.68 2.00 1.46
2.28 1.15 Scotchlite K37 Non-reactive Diluent: 2.01 2.08 1.88 2.23
1.63 2.55 1.28 Benzyl Alcohol Sub-total 61.78 60.56 64.26 57.64
69.09 51.66 75.68 Part B Components Water-based amine 16.58 17.11
15.50 18.38 13.41 20.97 10.55 curing agent: Cognis Waterpoxy 751
Deionized Water 4.77 4.92 4.46 5.29 3.86 6.03 3.04 Latex Emulsion:
Rohm 16.36 16.88 15.29 18.13 13.23 20.69 10.41 & Haas Rhoplex
MC- 1834 Non-reactive Diluent: 0.18 0.19 0.17 0.20 0.15 0.23 0.12
Benzyl Alcohol Defoamer: BYK- 0.33 0.34 0.31 0.36 0.27 0.42 0.21
Chemie BYK-011 (non- silicone) Sub-total 38.22 39.44 35.74 42.36
30.91 48.34 24.32 Examples 53 54 55 56 57 58 59 Weight % Weight %
Weight % Weight % Weight % Weight % Weight % Part A Components
Epoxy Resin: 12.12 13.51 12.49 14.29 11.09 15.81 9.62 Huntsman
GY6010 Reactive Diluent: Air 1.36 1.52 1.40 1.61 1.25 1.73 1.08
Products Epodil 748 Adhesion Promoter: 0.14 0.15 0.14 0.16 0.12
0.18 0.11 OSi Silquest A-187 Portland Cement: Type I 39.58 32.67
37.76 28.80 44.72 21.23 58.20 Hollow Spheres: 3M 2.28 2.54 2.35
2.68 2.08 2.97 1.81 Scotchlite K37 Non-reactive Diluent: 1.86 2.07
1.92 2.19 1.70 2.43 1.48 Benzyl Alcohol Sub-total 57.34 52.46 56.06
49.73 60.97 44.39 72.29 Part B Components Water-based amine 4.63
5.16 4.77 5.45 4.23 6.03 3.01 curing agent: Anquamine 287
Water-based amine 10.93 12.18 11.26 12.89 10.00 14.26 7.10 curing
agent: Waterpoxy 751 Titanium Dioxide: 11.86 13.22 12.22 13.98
10.85 15.47 7.71 Huntsman TR-60 Latex Emulsion: 15.05 16.77 15.50
17.73 13.77 19.61 9.77 Synthomer 29Y46 SBR Non-reactive Diluent:
0.17 0.19 0.18 0.20 0.16 0.22 0.11 Benzyl Alcohol Corrosion
Inhibitor: 0.02 0.02 0.02 0.02 0.02 0.02 0.01 Cortec MCI-2000
Sub-total 42.66 47.54 43.94 50.27 39.03 55.61 27.71
[0032] Further embodiments of the composition are described by the
following untested examples. The following examples are provide by
way of illustration not limitation, and the changes reflected are
equally applicable to each of the compositions specifically
described in Examples 1 through 59.
TABLE-US-00002 Untested Examples 60 61 62 63 64 Weight % Weight %
Weight % Weight % Weight % Part A Components Epoxy Resin Huntsman
GY6010 14.31 13.04 13.04 11.48 12.12 Reactive Diluent Air Products
Epodil 1.61 1.46 1.46 1.29 1.36 748 Adhesion OSi Silquest A-187
0.16 0.15 0.15 0.13 0.14 Promoter Portland Cement Type I 38.15 0 0
0 39.58 Type V 0 35.82 35.82 32.41 0 Pozzolan Calcined Kaolin 0
7.18 7.18 0 0 Fly Ash 0 0 0 6.71 0 Titanium Dioxide Huntsman TR-60
6.16 0 0 0 0 Hollow Spheres 1.61 2.34 2.34 4.27 2.28 Non-reactive
Rutgers Novares LS 2.20 2.00 2.00 1.76 1.86 Diluent 500 Sub-total
64.19 61.99 61.99 58.06 57.34 Part B Components Water-based amine
Cognis Waterpoxy 5.35 16.49 16.49 14.52 10.93 curing agent 751
Anquamine 287 12.65 0 0 0 4.63 Deionized Water 4.74 4.74 1.35 0
Titanium Dioxide Huntsman TR-60 0 0 0 11.30 11.86 Concrete Super
Lignotech Norlig 24C 0.20 0 0 0 0 Plasticizer Latex Emulsion
Synthomer 29Y46 17.41 0 0 0 15.05 SBR Rohm & Haas 0 16.27 16.27
14.33 0 Rhoplex MC-1834 Non-reactive Benzyl Alcohol 0 0.18 0 0 0
Diluent Rutgers Novares LS 0.2 0 0.18 0.16 0.17 500 Defoamer
BYK-Chemie BYK- 0 0 0.16 0 0 011 (non-silicone) Tego Foamex 805 0
0.33 0.17 0.29 0 (silicone) Corrosion Inhibitor Cortec MCI-2000 0 0
0 0 0.02 Sub-total 35.81 38.01 38.01 41.94 42.66 Untested Examples
65 Weight % Part A Components Liquid Amine Resin Huntsman Jeffamine
D-400 14.45 Portland Cement Lehigh Type I 42.01 Hollow Spheres
Scotchlite K-37 Glass Bubbles 2.41 Sub-total 58.86 Part B
Components Water-dispersed Epoxy Resin Resolution Epi-Rez 3510-W-60
41.14 Sub-total 41.14
[0033] Thus, in various embodiments, the composition of the present
invention broadly comprises some or all of the following
components: an epoxy resin of, in one embodiment, between 8.0% to
23.0% by weight, and, in another embodiment, between 10% to 42% by
weight; a powdered hydraulic cement of, in one embodiment, between
20.0% to 72.0% by weight and, in another embodiment, between 46% to
90% by weight; water in an amount at least sufficient to react with
the cement; a curing agent of, in one embodiment, between 5.0% to
21.0% by weight, and, in another embodiment, between 30% to 60%; a
non-reactive diluent of between 0.1% to 3.3% by weight; a reactive
diluent of, in one embodiment, between 0.8% to 2.6% by weight, and,
in another embodiment, between 1.1% to 4.8% by weight; a pigment of
between 6.0% to 24.0% by weight; an organosilicon adhesion promoter
of, in one embodiment, between 0.08% to 0.26% by weight, and, in
another embodiment, between 0.1% to 0.5%; a water-based latex resin
of between 4.0% to 31.0% by weight; a plurality of hollow spheres
of, in one embodiment, between 1.0% to 8.0% by weight, and, in
another embodiment, between 1% to 13% by weight; a defoamer of
between 0.5% to 1.0% by weight; a non-silicon defoamer of between
0.15% to 0.55% by weight; a silicone defoamer of between 0.15% to
0.55% by weight; a corrosion inhibitor of, in one embodiment,
between 0.01% to 2.4% by weight, and, in another embodiment, of
between 0.04% to 18.5% by weight; a concrete plasticizer of between
0.2% to 0.6% by weight; and/or a latex resin of between 30% to 50%
by weight. Characterized another way, one embodiment of the
composition of the present invention broadly comprises
approximately 90 parts epoxy resin mixed with approximately 10
parts reactive diluent to produce a mixture, and approximately 1
part hydraulic cement powder mixed with approximately 0.11 to 1.5
parts of the aforementioned mixture, to ultimately produce the
coating composition having between 0.80 to 1.30 equivalents of
total epoxy groups to 1.00 equivalent of reactive amine groups. In
various embodiments, the composition forms a coat having a
thickness of approximately between 2 mils to 15 mils.
[0034] Any of the disclosed embodiments of the claimed composition
may be used in a process to protectively coat a surface. The
process involves preparing the composition according to the present
invention, mixing the two parts with an appropriate amount of
water, and applying the coating to the surface. The formula may be
applied with a brush, roller or airless sprayer and will achieve a
high build film in a single application, although multiple coats
may be applied at the discretion of the user.
[0035] Thus, a waterborne epoxy composition is disclosed which
utilizes hydraulic cement powder as an element of the epoxy
composition to provide a desired initial application coat thickness
with good fluidity and enhanced cure time while still providing
protection against corrosion and other environmental threats. The
coating composition also provides corrosion resistance equal to
organic solvent based and solvent free coatings.
[0036] While preferred embodiments and particular applications of
this invention have been shown and described, it is apparent to
those skilled in the art that many other modifications and
applications of this invention are possible, including using the
teaching to develop coating compositions having three or more
components, without departing from the inventive concepts herein.
It is, therefore, to be understood that, within the scope of the
appended claims, this invention may be practiced otherwise than as
specifically described, and the invention is not to be restricted
except in the spirit of the appended claims. Though some of the
features of the invention may be claimed in dependency, each
feature has merit if used independently.
* * * * *