ACTIVE ANTI-ICE COATING, COATING MATERIAL AND METHOD

Abstract

The disclosure herein provides an active anti-ice coating, which is capable of releasing an anti-ice agent, which includes anti-ice agent reservoirs, which are embedded in a UV curable matrix material, for providing an effective anti-ice coating with an active anti-ice agent release over a long period of time.

Claims

1-14. (canceled)

15. An active anti-ice coating for releasing an anti-ice agent comprising an anti-ice liquid, wherein the anti-ice coating comprises a plurality of anti-ice agent reservoirs, wherein each of the plurality of anti-ice agent reservoirs are embedded in a solid photopolymerized matrix material, further wherein each of the anti-ice agent reservoirs comprises the anti-ice liquid, and wherein the anti-ice liquid is immiscible in a liquid photopolymerizable matrix material polymerized to provide the solid photopolymerized matrix material.

16. The active anti-ice coating according to claim 15, wherein the anti-ice coating comprises 3 to 20% by weight or 5 to 20% by weight of the anti-ice liquid.

17. The active anti-ice coating according to claim 15, wherein the photopolymerizable matrix material photopolymerized to provide the solid photopolymerized matrix material comprises: 60-80% by weight polyurethane diacrylates; and 20-40% by weight monomers; further comprising, based on a total mass of polyurethane diacrylates and monomers: 0.5-5% by weight photoinitiators, and 0-2% by weight additives.

18. The active anti-ice coating according to claim 15, wherein the anti-ice liquid is ethylene glycol.

19. An active anti-ice coating for releasing an anti-ice agent comprising an anti-ice liquid, wherein the anti-ice coating comprises a plurality of anti-ice agent reservoirs, wherein each of the plurality of anti-ice agent reservoirs are embedded in a solid, hydrophobic photopolymerized matrix material, further wherein each of the anti-ice agent reservoirs comprises the anti-ice liquid and wherein the anti-ice liquid is hydrophilic.

20. The active anti-ice coating according to claim 19, wherein the anti-ice liquid is ethylene glycol.

21. The active anti-ice coating according to claim 19, wherein the solid, hydrophobic photopolymerized matrix material is a reaction product of a hydrophobic liquid photopolymerizable matrix material.

22. The active anti-ice coating according to claim 21, wherein the hydrophobic, liquid photopolymerizable matrix material comprises: 60-80% by weight polyurethane diacrylates; and 20-40% by weight monomers; further comprising, based on a total mass of polyurethane diacrylates and monomers: 0.5-5% by weight photoinitiators, and 0-2% by weight additives.

23. An active anti-ice coating for releasing an anti-ice agent comprising an anti-ice liquid, wherein the anti-ice liquid has a freezing point lower property, and wherein the anti-ice coating comprises a plurality of anti-ice agent reservoirs embedded in a solid photopolymerized matrix material, wherein the solid photopolymerized matrix material is a reaction product of polyurethane diacrylates, monomers, and photoinitiators, and further wherein each of the anti-ice agent reservoirs comprises the anti-ice liquid.

24. The active anti-ice coating according to claim 23, wherein the solid photopolymerized matrix material is the reaction product of a mixture comprising: 60-80% by weight polyurethane diacrylates; and 20-40% by weight monomers; further comprising, based on a total mass of polyurethane diacrylates and monomers: 0.5-5% by weight photoinitiators, and 0-2% by weight of additives.

25. The active anti-ice coating according to claim 23, comprising 3 to 20% by weight or 5 to 20% by weight of the anti-ice liquid.

26. A method for producing an anti-ice coating material for forming an anti-ice coating, the method comprising: (a) providing a liquid photopolymerizable matrix material; (b) providing an anti-ice agent, wherein the anti-ice agent comprises an anti-ice liquid; and (c) introducing the anti-ice agent into the liquid photopolymerizable matrix material to form a non-aqueous emulsion comprising a first phase comprising the liquid photopolymerizable matrix material and a second phase comprising the anti-ice liquid.

27. The method according to claim 26, where providing a liquid photopolymerizable matrix material comprises at least one or more of: (a1) providing the matrix material such that the matrix material constitutes 80-97% by weight of the anti-ice coating; and/or (a2) providing a matrix material containing: 60-80% by weight of polyurethane diacrylate; and 20-40% by weight of monomers; further containing, based on a total weight of polyurethane diacrylate and monomers, 0.5-5% by weight photoinitiators, and 0-2% by weight additives.

28. The method according to claim 26, wherein the anti-ice liquid is ethylene glycol.

29. The method according to claim 26, wherein the non-aqueous emulsion is stabilized with a copolymer.

30. A method for producing an anti-ice coating, the method comprising: (a) providing a liquid photopolymerizable matrix material; (b) providing an anti-ice agent, wherein the anti-ice agent comprises an anti-ice liquid; (c) introducing the anti-ice agent into the liquid photopolymerizable matrix material to form an anti-ice coating material comprising a non-aqueous emulsion, wherein said non-aqueous emulsion comprises a first phase comprising the liquid photopolymerizable matrix material and a second phase comprising the anti-ice liquid; and (d) applying the anti-ice coating material to a surface area and photopolymerizing the anti-ice coating material; thereby producing an anti-ice coating.

31. The method according to claim 30, wherein the surface area is a surface area of a vehicle, an aircraft, a rotor, or a wind energy plant.

32. A vehicle, aircraft, rotor or wind energy plant comprising a surface area which is at least partly provided with an anti-ice coating according to claim 15.

33. A vehicle, aircraft, rotor or wind energy plant comprising a surface area which is at least partly provided with an anti-ice coating according to claim 19.

34. A vehicle, aircraft, rotor or wind energy plant comprising a surface area which is at least partly provided with an anti-ice coating according to claim 23.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Hereinafter embodiments of the disclosure herein will be illustrated by the corresponding, example drawings.

[0057] FIG. 1 is a schematic representation of a method for producing a UV curable anti-ice coating;

[0058] FIG. 2 is a schematic representation of a first step of a further method for producing a UV curable anti-ice coating, wherein FIG. 2 shows a procedure for synthesizing a glycogel, in which an anti freezing liquid is trapped in a UV curable matrix;

[0059] FIG. 3 is a second step of the further production method;

[0060] FIG. 4 is a schematic representation of a production of an active anti-ice coating from the coating material which has been produced according to FIG. 3 with an enlarged representation of an anti-ice agent reservoir;

[0061] FIG. 5 is an enlarged representation of the anti-ice agent reservoir;

[0062] FIG. 6 is a schematic representation of an active anti-ice coating, which has been produced according to the method of FIG. 2 to FIG. 5, with an enlarged representation of an anti-ice agent reservoir; and

[0063] FIG. 7 is an enlarged representation of a smaller part of the active anti-ice coating.

DETAILED DESCRIPTION

[0064] In the following the production of a first generation of biphasic UV curable anti-ice coating 14 is described by the representation in FIG. 1. The production starts with 80 to 97% by weight of a first component A and 3 to 20% by weight of a second component B, which are combined by copolymer CP to a coating material 10 for forming an active anti-ice coating 12.

[0065] As a first component in particular a liquid UV curable coating material 14 is used. An anti-ice liquid 16 having a freezing point lowering property is used for forming the second component B.

[0066] Examples for possible anti-ice liquids 16 are described in US 2014/0127516 A1, [0058].

[0067] Component B additionally contains 5 to 20% by weight of the copolymers CP (based on the mass of B).

[0068] According to a preferred embodiment a photo-induced curing liquid of 60 to 80% by weight of PUA (polyurethane diacrylate) and 20 to 40% by weight of monomers is used as the first component A. 0.5 to 5% by weight (based on the total mass of PUA and monomers) of photoinitiators and optionally 0 to 2% by weight (based on the total mass of PUA and monomers) of additives are added to the first component.

[0069] As a result an emulsion 18 of a first component A as a matrix material 20 and an anti-ice liquid 16 as component B which is dispersed therein is obtained. The emulsion 18 of matrix material 20 and anti-ice liquid 16 dispersed therein represents a liquid UV curable formulation 22. Applying 24 the formulation 22 and using UV light for UV curing 26 results in the active anti-ice coating 12 on a substrate 28. Surface areas of vehicles and aircrafts, of rotors and wind energy plants or the same may serve as a substrate 28.

[0070] The active anti-ice coating 12 has anti-ice agent reservoirs 30 which are embedded in the UV curable matrix material 20. The anti-ice liquid 16 is located in the anti-ice agent reservoirs. The anti-ice agent reservoirs 30 release the anti-ice liquid 16 on the surface of the anti-ice coating 12. Upon erosion of the active anti-ice coating 12 again and again new anti-ice reservoirs 30 are exposed.

[0071] The presence of the anti-ice liquid 16 on the surface of the anti-ice coating 12 leads to the prevention or the delay of the formation of ice.

[0072] In the following a method for producing a second generation of a biphasic UV curable coating based on UV glycogel 40 is illustrated in more detail by the representation in FIGS. 2 to 4. The method comprises two steps. A first step is indicated in FIG. 2, while a second step is shown in FIG. 3.

[0073] The first step relates to the synthesis of a UV glycogel 40. The second step relates to the dispersion of the UV glycogel 40 in the UV curable formulation of the first component A.

[0074] As is apparent from FIG. 2, the first step of forming the UV glycogel 40 starts with a third component C and a fourth component D, which are combined by copolymer CP and UV application to the UV glycogel 40.

[0075] UV curable monomers, for example based on polyethylene glycol (PEG), serve as third compound C.

[0076] The desired anti-ice liquid 16 is used as component D. In one example ethylene glycol (EG) is used. Further examples of possible anti-ice liquids 16 are described in US 2014/0127516 A1, [0058].

[0077] The weight of the glycogel comprises exemplary amounts of the third component D (ice liquid 16) in the range from 80 to 95%, preferably 80 to 90%, and of the fourth component C (UV curable monomers) in the range from 5 to 20%, preferably 10 to 20%.

[0078] The application of UV light 42 to the mixture of the third component C and the fourth component D leads to the formation of the UV glycogel 40 with anti-ice liquid 16 captured or trapped therein. This UV glycogel 40 forms a fifth component E which is applied in the second step, which will be hereinafter illustrated in more detail by FIG. 3. The fifth component E is an example for an anti-ice agent.

[0079] In this second step an emulsion 18 is formed from the first component Aas specified further aboveand the fifth component E (UV glycogel 40). As an example, 10 to 20% by weight are admixed in 80 to 90% by weight of the component A, based on the total mass of the emulsion 18.

[0080] In the emulsion 18 according to FIG. 3 the UV glycogel 40 and the anti-ice liquid 16 captured therein are dispersed in the still liquid UV curable matrix material 20.

[0081] The emulsion 18 represents the coating material 10, and the active anti-ice coating 12 is obtainable by applying 24 the emulsion 18 and UV curing 26. The first component A makes up 80 to 90% by weight of the emulsion 18. A liquid UV curable coating serves as a first component A, for example with a composition of 60 to 80% by weight of PUA, 20 to 40% by weight of monomers. 0.5 to 5% by weight of photoinitiators and 0 to 2% by weight of additives are added to this first component A based on the total amount of PUA and monomers.

[0082] In different embodiments the fifth component E may be dispersed in the emulsion 18 in a weight amount of 10 to 20%. The fifth component E is formed in particular by the UV glycogel 40 with anti-ice liquid 16 trapped therein.

[0083] In an example the fifth component E is made of acrylate monomers from the component C, to which photoinitiators and eventually additives may be added, and anti-ice liquid from the component D.

[0084] The coating material 10, which is present as emulsion 18, then forms a liquid UV curable formulation 22, which turns into the active anti-ice coating 12 on the substrate 28 upon its application 24 and UV curing 26.

[0085] In the UV glycogel 40 the anti-ice liquid 16 is also captured or trapped in a UV curable matrix.

[0086] Thus, the finished product of an anti-ice coating 12 comprises the anti-ice agent reservoirs 30 with anti-ice liquid 16 trapped or captured in matrix material 20, 40, in order to release anti-ice liquid 16 on the surface.

[0087] FIGS. 4 and 5 show an enlarged representation of the anti-ice agent reservoirs 30. Inside there are the anti-ice liquid 16 and monomers, which on the outside are linked to the matrix material 20 by copolymer CP.

[0088] Thus, in the finished anti-ice coating 12 the UV cured matrix material of the first component A with an anti freezing phase 44 embedded therein is provided. In one embodiment this anti freezing phase 44, which forms the anti-ice agent reservoirs 30, comprises 1 to 20% by weight of anti-ice liquid, 16.0 to 20% of monomers and 0 to 5% of photoinitiators and copolymer surfactants.

[0089] An active anti-ice coating 12 with excellent erosion resistance and encapsulated anti-ice agent reservoirs 30 is thus obtained, which enables a sustained continuing release of anti-ice liquid 16 during the use of the anti-ice coating 12.

[0090] In the following specific examples of UV curable coating materials for forming an anti-ice coating are given, which are obtained with one of the above illustrated production methods.

EXAMPLE 1

[0091] A UV curable first matrix I with the following composition is produced as component A:

TABLE-US-00001 PUA-UVU 9321HD12 from the company Polymer 58% Technology Photomer 4172F from the company Cognis 20% Bisomer PEA6 from the company Cognis 10% SR 268US from the company Sartomer 10% TPO (Pi) photoinitiator from the company BASF 2%

[0092] From this a coating material with the following composition is produced according to the above-mentioned method of the first generation:

TABLE-US-00002 UV curable first matrix I 89.3% copolymer surfactants 1.8% ethylene glycol 8.9%

EXAMPLE 2

[0093] A UV curable second matrix II with the following composition is produced as component A:

TABLE-US-00003 UVP 6021-HD15 4 from the company Ssunin 77.2% SR 355 from the company Arkema 8.7% Si. acrylate A from the company Bluestar 2.3% Butyle acrylate monomers from the company Aldrich 10% Chivacure 173 from the company Chitec 1.8%

[0094] From this a coating material with the following composition is produced according to the above-mentioned method of the first generation:

TABLE-US-00004 UV curable second matrix II 89.3% copolymer surfactants 1.8% ethylene glycol 8.9%

EXAMPLE 3

[0095] A UV curable third matrix III with the following composition is produced as component A:

TABLE-US-00005 UVP 6021-HD15 from the company Ssunin 88% SR 355 from the company Arkema 10% Chivacure 173 from the company Chitec 2%

[0096] From this a coating material with the following composition is produced according to the above-mentioned method of the first generation:

TABLE-US-00006 UV curable third matrix III 87.5% copolymer surfactants 2.5% ethylene glycol 10%

[0097] In the examples ethylene glycol is used as the anti-ice liquid which is embedded in the UV curable matrix.

[0098] In tests the coating material of example 1 has shown the lowest ice adhesion value; the examples 2 and 3 also showed promising results.

[0099] The method of the second generation as described further above differs from the above-mentioned examples additionally in that the anti-ice liquid is first captured in a UV polymerizable gel and that this mixture (instead of the anti-ice liquid in examples 1 to 3) and the matrix are the processed to an emulsion.

[0100] In the following specific examples for the second generation are illustrated in more detail.

EXAMPLE 4

[0101] A glycogel (designated as glycogel 131) with the following composition is synthesized as component E:

TABLE-US-00007 SR610 from the company Arkema 1.96% Bisomer PEA from the company GEO Speciality 7.84% Chemicals Irgacure 2959 from the company BASF 0.2% ethylene glycol 90%

[0102] The substances are mixed and submitted to a UV irradiation with a UV dose of 5,000 mJ for the fusion or the gel formation for producing the glycogel.

[0103] A UV curable fourth matrix IV with the following composition is produced as component A:

TABLE-US-00008 PUA-UVU 9321HD12 from the company Polymer 58% Technology Photomer 4172F from the company Cognis 20% Bisomer PEA6 from the company Cognis 10% SR 268US from the company Sartomer 10% Chivacure 173 from the company Chitec 2%

[0104] Then an emulsion with the following composition is produced from the matrix IV and glycogel 131 (components A and E):

TABLE-US-00009 UV curable matrix IV 88.2% copolymer surfactant 2% Glycogel 131 8.9%

EXAMPLE 5

[0105] A glycogel (designated as Glycogel 121) with the following composition is synthesized as component E:

TABLE-US-00010 SR344 from the company Arkema 2% Bisomer PEA from the company GEO Speciality 7.8% Chemicals Irgacure 2959 from the company BASF 0.2% EG (ethylene glycol) 90%

[0106] The substances are mixed and submitted to a UV irradiation with a UV dose of 1,000 mJ for the fusion or the gel formation for producing the glycogel.

[0107] A UV curable fifth matrix V with the following composition is produced as component A:

TABLE-US-00011 UVP 6021-HD15 4 from the company Ssunin 88% SR 355 from the company Arkema 10% Chivacure 173 from the company Chitec 2%

[0108] Then an emulsion with the following composition is produced from matrix V and Glycogel 131 (components A and E):

TABLE-US-00012 UV curable matrix V 88.2% copolymer surfactant 2% Glycogel 121 8.9%

[0109] The UV curing fusion in examples 4 and 5 was carried out with an Arc bulb LC6B Benchtop Conveyor.

[0110] While at least one exemplary embodiment of the invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a, an or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.

LIST OF REFERENCE NUMERALS

[0111] A first component [0112] B second component [0113] C third component [0114] D fourth component [0115] E fifth component [0116] CP copolymer [0117] 10 coating material [0118] 12 active anti-ice coating [0119] 14 liquid UV hardable coating [0120] 16 anti-ice liquid [0121] 18 emulsion [0122] 20 matrix material [0123] 22 liquid UV curable coating [0124] 24 Applying [0125] 26 UV curing [0126] 28 substrate [0127] 30 anti-ice agent reservoir [0128] 40 UV glycogel [0129] 42 UV application [0130] 44 anti freezing phase