CA1120253A - Zinc-rich powders - Google Patents

Zinc-rich powders

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Publication number
CA1120253A
CA1120253A CA000283097A CA283097A CA1120253A CA 1120253 A CA1120253 A CA 1120253A CA 000283097 A CA000283097 A CA 000283097A CA 283097 A CA283097 A CA 283097A CA 1120253 A CA1120253 A CA 1120253A
Authority
CA
Canada
Prior art keywords
zinc
powder
epoxy resin
rich
homogeneous
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000283097A
Other languages
French (fr)
Inventor
Leizer Balk (Deceased)
James S. Sojkowski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pratt & Lambert Ltd
Original Assignee
Pratt & Lambert Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pratt & Lambert Ltd filed Critical Pratt & Lambert Ltd
Application granted granted Critical
Publication of CA1120253A publication Critical patent/CA1120253A/en
Expired legal-status Critical Current

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Abstract

ABSTRACT OF THE DISCLOSURE
A zinc-rich electrostatic powder is prepared comprising zinc incorporated homogeneously in an epoxy resin powder.

Description

1 Zinc-rich electrostatic powders are employed as
2 coatings to protect iron or steel parts from corrosion.
3 The zinc in the coating acts as a sacrificial metal to protect
4 the iron base.
Coatings of this general type are known and even 6 zinc-containing electrostatic powders are known- U.S. Milla~ patent 7 3,770,482 describes one such heterogeneous powder. Millar employs 8~ a two layer system. Millar employs up to 30% of zinc, col. 5, 9 lines 13-40.
It is also known to make a free flowing powder for 11 fusion coating of metals including steel employing a mixture of 12 (A) an epoxide resin, a siloxane resin, and a polycarboxylic 13 acid anhydride and (B) a filler, U.S. Bo~d paten~ 3,170,890 14 Component (B) can be 25 to 70~ of the total of (A) and (B~, col. 3, lines 40-55 and the claims. Boyd mentions zinc as a 16 filler on col. 3, line 55. ~e makes a heterogeneous mixture of 17 the powder which can then be applied to the mPtal substrate by 18 conventional procedures, e.g., fluidized bed techniques~
l9 U.S.Manasia patent 3,336,251 shows employing zinc dust as a filler for an epoxy resin in an amount of 1 up to 150 parts 21 per lO0 parts of the resin. Manasia simply dry blends ~is 22 mixture and applies his mixture to a metal substrate, e.g., 23 steel by a fluidized bed procedure.
24 U.S. Car~nanian patent 3,939,020 discloses applying a coating containing an epoxy resin, powdered zinc, inorganic ,. .. -...... ~ ~
..
.
, . ~ . ...

s~

1 fibers and barium sulfate to a rotor, e.~., col. 1, lines 42-46.
2 U.S.Kenyon patent 3,518,221 discloses a molding composition 3 comprising an inorganic fiber enveloped in a first epoxy resin 4 and a second epoxy resin surrounding the enveloped fiber, eOg., claim 6. Powdery fillers can also be used, col. 9, lines 23-26.
It has now been found that homogeneous zinc-rich 7 powders/ e.g., electrostatic powders, can be prepared by 8 ~ incorporating zinc powder into an epoxy resin melt and thereby, 9 the zinc is uniformly distributed-without any density gradient in the finished free-flowing powder.
11 The zinc powder can be blended with molten epoxy 12 resin in a conventional manner in a screw fed melt compounder 13 followed by cooling and grinding the solid to form a powder 14 compound or else the zinc powder and epoxy resin in powder form can be mixed and the preblended powder homogenized on a heated 16 two-roll mill, at a temperature suficient to soften or melt the 17 resin, but insufficient to cure it during its working time on 18 the mill. Thus a temperature of 180F. can be used with PpOxy 19 resins that soften below this temperature. Alternatively, the epoxy resin in powder, lump or flake form is added to the heated 21 two roll mill and after it is in softened or molten form, the zinc 2~ powder is added and milling continued until a homogeneous blend 23 is obtained. After removal of the homogeneous blend obtained 24 in either of the two milling procedures just described, the product is al]owed to cool to solid form and ground to a powder.

~ .

- ~ ~

ll~DZ53 1 Normally the curing aid is added to the epoxy resin 2 prior to mixing with the æinc powder whether the mixing is 3 accomplished by using a screw fed mel-t compounder or by using 4 hot rolls~ In this manner there is obtained a high weight %
of zinc powder homogeneously blended with epoxy resin powder.
6 The zinc is 75 to 90%- of the total weight of the composition.
7 As stated, after incorporation of the zinc in the molten resin or 8 after milling the product is cooled to form a solid which is 9 then ground to a powder. The exact si2e of the powder is not particularly critical, but it is usually small enough to pass 11 100 mesh (Tyler sieve series~. For fluid bed application to the 12 metal substrate, e.~., iron or steel, the composition is ground 13 to pass 60 mesh or to pass 200 mesh for spray or electrostatic 14 fluid bed application.
Any of the conventional solid epoxy resins or mixtures 16 o two or more such epoxy resins can be used. There can also 17 be used any of the conventional curing agents for the epoxy 18 resin. Thus, there can be used, for example, as curing agents 19 dicyandiamide, P-108~(a mixture of an imidazole and dicyandiamide having a melting point range of 40-200C.~, solid cyclic carboxylic 21 acid anhydrides, e.g., trimellitic anhydride, phthalic anhydride, 22 cyclopentane dianhydride, tetrachlorophthalic anhydride and the 23 like.
24 Illustrative of suitable epoxy resins are Epirez S22F
(a bisphenol A-epichlorhydrin resin with a weight per epoxide B
- . .. , ~ .
.

)Z53 1 (WPE) of 600, Durran's Melting Point of 80C. and supplied 2 by Celanese), DRH 201 (a linear solid bisphenol A-epichlorhydrin 3 resin having a WPE of about 750, a Durran's Melting Point of 4 90C. and supplied by Shell), DRH (an epoxy resin identical with DRH 201, except DRH 203 also contains 5% of Modaflow, a flowaid 6 supplied by Monsanto), DER-667 (a solid bisphenol A-epichlor~
7 hydrin resin with a WPE of 1600-2000, a Durran's Melting Point 8 of 115-130C. and supplied by Dow), XU-21~(a solid bisphenol A-9 epichlorhydrin resin with an average WPE of 700 and supplied by Ciba-Geigy), Epon~1001 (bisphenol A-epichlorhydrin resin, 11 WPE 450-550, Durran's Melting Point 65-74C. and supplied by 12 Shell). There can be even used a small amount of liquid 13 bisphenol A-epichlorhydrin, e.g., Epon~828, having a WPE of 14 180-195 and a viscosity of 100-160 poises, supplied by Shell, providing the overall epoxy resin in a solid.
16 The zinc-rich epoxy hot melt powder compositions of 17 the invention can replace conventional zinc 18 galvanizing/plating finishes for iron or steel and offer true 19 galvanic sacrificial protection.
The compositions of the invention have excellent 21 adhesion to iron and steel and when applied thereto, e.~., by 22 spray or electrostatic fluid bed technique, provide a continuous 23 film coating for iron or s~eel.
24 In a series of tests of formulations within the invention, the formulation containing 90% zinc provided the best
- 5 -~. .

.

~20~53 1 adhesion to steel and the formulatioll with 85% zinc had the best 2 visual appearance after the coated steel had been subjected 3 to salt attack.
4 Unless otherwise indicated all parts and percentages are by weight.
6 The compositions preferably consist essentially of the
7 zinc dust and epoxy resin. As previously indicated there can, of
8 course, be included a curing agent for ~he epoxy resin to
9 improve the cured film properties and also a small amount of a flow modifier can be included. Small amounts of silica aerogels 11 can be included, e.~., 0.2~ of Cab-O-Si~, ~ flame hydrated silica~
12 Examples of suitable formulations are the following:

14 Example 1 DRH-201 12.0 16 DRH-203 3.0%
17 Zinc Dust (finely ground 18 100~ zinc powder) 85.0~ ~
19 ~, 20 Example 2 21 Epirez 522F 20.0 parts 22 DRH-203 5.0 parts 23 Zinc Dust 75.0 parts 24 P-108~ 1.56 parts 101.56 parts 1 Examples 3 and 4 2 Example 3 Example 4 3 Epirez 522F 11.22~ 7.48%
4 DRH-203 3.00~ 2.00%
Zinc Dust 85.00% 90.00%
6 P-108~ 0.7~% 0.52~

9 Examples 5, 6 and 7 Example 5 Example 6 Example 7 11 DRH-203 5.0~ 1~84% 3.00%

12 Zinc Dust 75.0~ 75~00% 85.00 13 P-108~ 1.3~ - 0.7 14 Modified Trimellitic Anhydride Curing Agent - 6.42%

16 DER-667 18.7~ - -17 Epirez~522F - 16.74%

18 X~-214~ - _ 11.22%

21 In tests on st~el panels both the compositions of 22 Examples 5 and 7 had good to excellent adhesion to steel and the 23 composition of Example 7 had 0-creepage from the scribe marks 24 and no blistering or rust spotting.
The compositions containing 85%-zinc (Example 7) and ~, .

1 90% zinc (Example 4) had better anticorrosive results when applied to the steel than the compositions of Example 5, thus 3 indicating superior sacrificial properties as shown by ~alt 4 fog exposure at times of 100, 200, 300, 400 and 500 hours.
In the above tests the homogeneous zinc-rich 6 compositions were applied to the steel by the conventional 7 fluidized bed procedure. Coatings of 2 mil, 4 mil, 6 mil, 8 8 mil, 9.4 mil and 12.0 mil thickness were applied to the steel.
9 The composition of Example 2 was cured on the steel for 15 minutes at 180C. and in other tests was cured on the 11 steel for 7 minutes at 210C. The other compositions containing 12 curing agents were similarly cured at 180C. for 15 minutes 13 or at 210C. for 7 minutes. A cure cycle of 15 minutes at 14 180C. is preferred. Also it is preferred to form a film build of 4-10 mils of the homogeneous zinc-epoxy composition 16 on the iron or steel, e.g., cold rolled steel strip or steel 17 rods-~2 . .

.

Claims (24)

The embodiments of the invention in which an exclu-sive property or privilege is claimed are defined as follows:
1. A homogeneous zinc-rich powder composition con-sisting essentially of zinc powder and a curable epoxy resin powder, the zinc being 75 to 90% by weight of the total of zinc and epoxy resin.
2. A zinc-rich composition according to Claim 1, wherein the epoxy resin is a bisphenol A-epichlorhydrin resin.
3. A zinc-rich composition according to Claim 2, wherein the epoxy resin has a WPE of 450 to 2000.
4. A zinc-rich composition according to Claim 2, wherein the zinc is 85 to 90% of the total of zinc and epoxy resin.
5. An iron or steel substrate having a continuous sacrificial coating of the product obtained by curing a homogeneous zinc-rich powder composition consisting of zinc powder and a curable epoxy resin powder thereon, the zinc being 75 to 90% by weight of the total of zinc and epoxy resin.
6. A coated substrate according to Claim 5, wherein the epoxy resin is a bisphenol A-epichlorhydrin resin.
7. A coated substrate according to Claim 6, wherein the zinc is 85 to 90% by weight of the total of zinc and epoxy resin.
8. A coated substrate according to Claim 7, wherein the coating has a thickness of 4 to 10 mils.
9. A coated substrate according to Claim 5, wherein the coating has a thickness of 2 to 12 mils.
10. A homogeneous zinc-rich composition according to Claim 1 consisting of zinc powder and a curable epoxy resin powder, the zinc being 75 to 90% by weight of the total of zinc and epoxy resin.
11. An iron or steel substrate according to Claim 5 having a continuous 4 to 10 mil thick sacrificial coating of the product obtained by curing a homogeneous zinc-rich powder composition consisting of zinc powder and a curable epoxy resin powder thereon, the zinc being 75 to 90% by weight of the total of zinc and epoxy resin.
12. A homogeneous zinc-rich powder composition con-sisting essentially of zinc powder and a curable epoxy resin powder prepared by a process comprising blending the zinc powder with the epoxy resin in molten state until a homogeneous mixture is produced, the zinc is 75%-90% by weight of the total of zinc and epoxy resin, cooling the mixture to solid form and thereafter grinding the solid to a powder form.
13. The zinc-rich composition according to Claim 12, wherein the epoxy resin is a bisphenol A-epichlorhydrin resin.
14. The zine-rich eomposition according to Claim 13, wherein the epoxy resin has a WPE of 450-2000.
15. The zinc-rich composition according to Claim 14, wherein the zinc is 85%-90% of the total of zinc and epoxy resin.
16. A substrate having a continuous sacrificial coating of the product obtained by curing a homogeneous zinc-rich powder composition consisting of zinc powder and a curable epoxy resin powder thereon, prepared by a process comprising blending the zinc powder with the epoxy resin in molten state until a homogeneous mixture is pro-duced, the zinc is 75%-90% by weight of the total of zinc and epoxy resin, cooling the mixture to solid form and then grinding the solid to a powder form.
17. A coated substrate according to Claim 16, wherein the epoxy resin is a bisphenol A-epichlorhydrin resin.
18. A coated substrate according to Claim 17, wherein the zinc is 85%-90% by weight of the total of zinc and epoxy resin.
11 l9. A coated substrate according to Claim 18, wherein the coating has a thickness of 4-l0 mils.
20. A coated substrate according to Claim l9, wherein the coating has a thickness of 2-12 mils.
21. A coated substrate according to Claim 20, wherein the substrate is a metal selected from the group consisting of iron and steel.
22. A homogeneous zinc-rich composition consisting essentially of zinc powder and a curable epoxy resin powder prepared by a process comprising blending the zinc powder with the epoxy resin in molten form until a homogene-ous mixture is produced, the zinc is 75%-90% by weight of the total of zinc and epoxy resin, cooling the mixture to solid form and thereafter grinding the solid to powder form.
23. A homogeneous zinc-rich powder composition con-sisting essentially of zinc powder and a curable epoxy resin powder prepared by a process comprising blending the zinc powder and epoxy resin powder, the zinc is 75%-90% by weight of the total of zinc and epoxy resin, then heating the pre-blended mixture to a temperature sufficient to melt the resin without curing it, while continuously blending the mixture until a homogeneous product is obtained, cooling the product to a solid form and thereafter grinding the solid to form a powder.
24. A homogeneous zinc-rich powder composition con sisting essentially of zinc powder and a curable epoxy resin powder prepared by a process comprising heating the epoxy resin powder, the zinc is 75%-90% by weight of the total of zinc and epoxy resin, to a temperature sufficient to melt the resin without curing it, and thereafter adding the zinc powder with continuous blending until a homogeneous product is obtained cooling the product to a solid form and thereafter grinding the solid to form a powder.
CA000283097A 1976-11-10 1977-07-19 Zinc-rich powders Expired CA1120253A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US74073176A 1976-11-10 1976-11-10
US740,731 1976-11-10

Publications (1)

Publication Number Publication Date
CA1120253A true CA1120253A (en) 1982-03-23

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ID=24977820

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000283097A Expired CA1120253A (en) 1976-11-10 1977-07-19 Zinc-rich powders

Country Status (2)

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CA (1) CA1120253A (en)
ZA (1) ZA774151B (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6346292B1 (en) * 1998-10-15 2002-02-12 Rohm And Haas Company Corrosion- and chip-resistant coatings for high tensile steel
US6663968B2 (en) 2000-11-01 2003-12-16 Rohm And Haas Company Corrosion-and chip-resistant coatings for high tensile steel
US8574708B2 (en) 2007-10-31 2013-11-05 Akzo Nobel Coatings International B.V. Thin chip resistant powder topcoats for steel
US8647745B2 (en) 2008-01-25 2014-02-11 Akzo Nobel Coating International B.V. Powder coating compositions having a substantially non-zinc containing primer
US10011736B2 (en) 2009-07-29 2018-07-03 Akzo Nobel Coatings International B.V. Powder coating compositions capable of having a substantially non-zinc containing primer
US10344178B2 (en) 2009-04-03 2019-07-09 Akzo Nobel Coatings International B.V. Powder corrosion and chip-resistant coating

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6346292B1 (en) * 1998-10-15 2002-02-12 Rohm And Haas Company Corrosion- and chip-resistant coatings for high tensile steel
US7018716B2 (en) 1998-10-15 2006-03-28 Rohm And Haas Company Corrosion-and chip-resistant coatings for high tensile steel
US6663968B2 (en) 2000-11-01 2003-12-16 Rohm And Haas Company Corrosion-and chip-resistant coatings for high tensile steel
US8574708B2 (en) 2007-10-31 2013-11-05 Akzo Nobel Coatings International B.V. Thin chip resistant powder topcoats for steel
US8647745B2 (en) 2008-01-25 2014-02-11 Akzo Nobel Coating International B.V. Powder coating compositions having a substantially non-zinc containing primer
US10344178B2 (en) 2009-04-03 2019-07-09 Akzo Nobel Coatings International B.V. Powder corrosion and chip-resistant coating
US10011736B2 (en) 2009-07-29 2018-07-03 Akzo Nobel Coatings International B.V. Powder coating compositions capable of having a substantially non-zinc containing primer
US10550283B2 (en) 2009-07-29 2020-02-04 Akzo Nobel Coating International B.V. Powder coating compositions capable of having a substantially non-zinc containing primer

Also Published As

Publication number Publication date
ZA774151B (en) 1978-12-27

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