COATING COMPOSITION FOR THE PROTECTION OF COMPLEX METAL STRUCTURES AND COMPONENTS

Abstract

A coating composition for application to a component or structure has cellulose acetate, a plasticizer with an antioxidant, a corrosion inhibitor with an antioxidant, a vegetable oil, and a stabilizer. The plasticizer is linseed oil. The corrosion inhibitor is canola oil. The vegetable oil is epoxidized soybean oil. The stabilizer is titanium dioxide. These components are intimately mixed together so as to form a solid mixture. The solid mixture is converted into a solid state and applied to the component or structure. The liquid state is then dried on the component or structure for a period of time.

Claims

1. A coating composition for application to a component or structure, the coating composition comprising: a cellulose acetate; a plasticizer; a corrosion inhibitor; a vegetable oil; and a stabilizer, in which the cellulose acetate, the plasticizer, the corrosion inhibitor, the vegetable oil, and the stabilizer are mixed together.

2. The coating composition of claim 1, said vegetable oil being epoxidized.

3. The coating composition of claim 1, said plasticizer being linseed oil having an antioxidant.

4. The coating composition of claim 1, said cellulose acetate being canola oil having a antioxidant.

5. The coating composition of claim 1, said vegetable oil being epoxidized soybean oil.

6. The coating composition of claim 1, said stabilizer being titanium dioxide.

7. The coating composition of claim 1, said cellulose acetate being between 39% and 45% by weight of the total composition, said plasticizer being between 22% and 25% by weight of the total composition, said corrosion inhibitor being between 22% and 25% by weight of the total composition, said vegetable oil being 7% by weight of the total composition, said stabilizer being 3.4% by weight of the total composition.

8. The coating composition of claim 7, further comprising: carbon black mixed with cellulose acetate, said plasticizer, said corrosion inhibitor, said vegetable oil and said stabilizer.

9. The coating composition of claim 8, said carbon black being 0.6% by weight of the total composition.

10. The coating composition of claim 1, said cellulose acetate being between 39% and 45% by weight of the total composition, said plasticizer being a linseed oil of between 22% and 25% by weight of the total composition, said corrosion inhibitor being canola oil of between 22% and 25% by weight of the total composition, said vegetable oil being epoxidized soybean oil in an amount of 7% by weight of the total composition, said stabilizer being titanium dioxide in an amount of 3.4% of the total composition.

11. A method of applying a coating to a component or a structure, the method comprising: mixing cellulose acetate, a plasticizer, a corrosion inhibitor, a vegetable oil, and a stabilizer together so as to form a solid mixture; heating the solid mixture so as to convert the solid mixture into a liquid state; covering the component or the structure with the liquid state; and drying the liquid state on the component or structure for a period of time.

12. The method of claim 11, the step of heating comprising: heating the solid mixture to a temperature of greater than 160° C.

13. The method of claim 11, the step of heating comprising: heating the solid mixture to a temperature of between 160° C. and 170° C.

14. The method of claim 11, the step of covering comprising: spraying the liquid state of the mixture onto the component or the structure.

15. The method of claim 14, the step of covering comprising: spraying only a single coating of the liquid state of the mixture onto the component or the structure.

16. The method of claim 11, the step of drying comprising: drying the liquid state for a period of time of less than 5 minutes.

17. The method of claim 11, said cellulose acetate being between 39% and 45% by weight of the total mixture, said plasticizer being between 22% and 25% by weight of the total mixture, the corrosion inhibitor being between 22% and 25% by weight of the total mixture, said vegetable oil being 7% by weight of the total mixture, said stabilizer being 3.4% by weight of the total mixture.

18. The method of claim 11, said plasticizer being a linseed oil having an antioxidant, said corrosion inhibitor being canola oil having an antioxidant, said vegetable oil being an epoxidized soybean oil, said stabilizer being titanium dioxide.

19. The method of claim 11, said cellulose acetate being between 39% and 45% by weight of the total mixture, said linseed oil being between 22% and 25% by weight of the total mixture, said canola oil being between 22% and 25% by weight of the total mixture, said epoxidized soybean oil being 7% by weight of the total mixture, said titanium dioxide being 3.4% by weight of the total mixture.

20. The method of claim 11, further comprising: mixing carbon black with the cellulose acetate, said plasticizer, said corrosion inhibitor, said vegetable oil and said stabilizer, said carbon black being 0.6% by weight of the total mixture.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0047] FIG. 1 is a diagram showing the various factors that create corrosion.

[0048] FIG. 2 is an illustration of the interface between the water droplet, the substrate and air.

[0049] FIG. 3 shows the application of the composition of the present invention onto a subsea structure.

DETAILED DESCRIPTION OF THE INVENTION

[0050] The polymeric coating of the present invention has a variety components. In particular, the components of the coating of the present invention can include cellulose acetate, a plasticizer, a corrosion inhibitor, a vegetable oil, and a stabilizer. The cellulose acetate, the plasticizer, the corrosion inhibitor, the vegetable oil, and the stabilizer are intimately mixed together. The plasticizer is a linseed oil having an antioxidant. The corrosion inhibitor is canola oil having an antioxidant. The vegetable oil is epoxidized soybean oil. The stabilizer is titanium dioxide. Carbon black can be mixed with the cellulose acetate, the plasticizer, the corrosion inhibitor, the vegetable oil and the stabilizer.

[0051] Experiments were conducted with mixtures of the present invention. The following mixture was found to have great temperature stability and strength. This particular formulation is made up of 39% by weight of cellulose acetate, 25% by weight of linseed oil with an antioxidant, 25% by weight of canola oil with an antioxidant, 7% epoxidized soybean oil, 3.4% titanium dioxide, and 0.6% carbon black.

[0052] This formulation was further altered so as to provide a superior quality product. This alternative formulation is comprised of 45% by weight of cellulose acetate, 22% by weight of linseed oil with an antioxidant, 22% by weight of a canola oil with an antioxidant, 7% by weight of epoxidized soybean oil, 3.4% by weight of titanium dioxide, in 0.6% by weight of carbon black. This formulation was found to be particularly applicable to both submerged structures and surface structures. Compositions ranging between the component ratios expressed in each of the above formulations was felt to be also significantly applicable to components or structures, whether submerged or surface-located.

[0053] This composition provides a unique sprayable coating system that can be applied to address a wide range of subsea corrosion issues. The composition is particularly applicable to the protection of bolted or jointed junction/connections, or other operable metallic components. The present invention overcomes the shortcomings of existing corrosion control techniques in order to provide a reliable and sustainable solution. The composition is a standalone product. It does not have to be used with other products in order to get the proper result.

[0054] The composition of the present invention provides a significant longevity of protection. It is believed that the composition can provide protection for over thirty years. The composition is easily and quickly applied, dries very rapidly, is removable and reusable, and is also ecologically safe. Damage to this composition can be repaired in the field very easily at the point of damage. All that is necessary is to remove the damaged material and reapply the composition to the damaged area. The composition will adhere to itself since the material is applied in a molten state. This composition, once applied, can be removed with a knife by hand. As such, potential damage to the subsea structure is avoided. There is no need for expensive ancillary equipment. As such, the present composition provides a very time-efficient process. Importantly, when applied to a subsea structure, the composition becomes flexible, impact resistant and corrosion resistant. The flexibility facilitates the ability of the composition to better adhere to and to distribute forces to the structure. The subsea pressure can also serve to seal the composition against the subsea structure. The composition further avoids bubble formation when placed under the subsea pressure.

[0055] The composition of the present invention is a solid product at ambient conditions below 160° C. As such, heat is required to melt the solid product to a liquid state. Once in a liquid state, the composition of the present invention can be applied to metallic surfaces. Once the liquid composition of the present invention makes contact with the surface, this composition will take a form of the shape of the surface and dry very rapidly so as to provide a protective cocoon. Within this cocoon, there are active corrosion-inhibiting agents which create a membrane layer between the substrate and the protective coating. FIG. 3 shows the application of the protective coating. This membrane layer eradicates any further surface corrosion as well as ensures that foreign contaminates cannot ingress under the encapsulation. When the composition is used on bolted structures, such as that shown in FIG. 3, the inhibiting oils penetrate the thread of the nut and the bolt to ensure that the bolt does not seize internally to the structure and the encapsulation.

[0056] With reference to FIG. 3, the coating has been applied to a flanged connection 10. The flanged connection includes an upper flange member 12, a lower flange connection 14, and bolts 16 and 18. The bolts 16 and 18 are threadedly secured with the flanges 12 and 14 so as to secure the flanges together. The corrosion inhibitor is formed as inner layer 20. The inner layer 20 acts immediately and actively when in contact with the surfaces of the flange connection 10. The polymeric resin 22 is on the outside of the corrosion inhibitor and acts as passive protection. The polymeric resin 22 encapsulates the flange connection 10 and avoids ingress of suspended particles, water, air, etc.

[0057] The flexible coating only creates adhesion through encapsulation. As such, the coating can be removed from the component or structure in small portions or removed as a whole with a knife in an matter of seconds. Another advantage to the composition of the present invention is that there is no surface tension. As such, the composition can be applied to a moving part, such as a valve. The economic advantages of the present invention are obvious when compared to other solvent-based products, such as paints or epoxies. The composition of the present invention only requires minimal surface preparation prior to application. This surface preparation can include the removal of loose material, grease, oil build-up, and moisture. The composition of the present invention does not create any waste during the application process. The application-to-dry time is 1/20 the cure time for most paint coatings. Only one coating of the composition of the present invention is necessary. The coating composition of the present invention has a drying time of less than five minutes. As such, the present invention is able to provide protection very quickly. There is no need to apply a primer, as in the case of a paint coating. Ultimately, with paint coatings, several coatings of paint are required in order to provide the necessary protection. This can take in excess of two hours to cure. The composition of the present invention can be removed entirely from a substrate and then can be melted down and reused up to six times. The composition of the present invention continue to be reused while retaining its complete anti-corrosion properties. The composition of the present invention does not have a hazzard classification for transport or disposal. As such, the present invention avoids any expensive disposal cost.

[0058] Due to the active nature of the composition of the present invention, along with its ability to retain flexibility, the material can expand and contract along with the component or structure that it is protecting. Many other corrosion control products do not have sufficient elasticity or flexibility. As such, this can cause the prior art compositions to perish and crack, especially when subjected to large temperature variations.

[0059] The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the described composition or the steps in the described method can be made which the scope of the present claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.