WO2010123028A1 - 導電性金属塗料及び導電性金属塗料による防食方法並びに防食補修方法 - Google Patents
導電性金属塗料及び導電性金属塗料による防食方法並びに防食補修方法 Download PDFInfo
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- WO2010123028A1 WO2010123028A1 PCT/JP2010/057061 JP2010057061W WO2010123028A1 WO 2010123028 A1 WO2010123028 A1 WO 2010123028A1 JP 2010057061 W JP2010057061 W JP 2010057061W WO 2010123028 A1 WO2010123028 A1 WO 2010123028A1
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/24—Electrically-conducting paints
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
- C09D5/10—Anti-corrosive paints containing metal dust
- C09D5/103—Anti-corrosive paints containing metal dust containing Al
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/20—Conductive material dispersed in non-conductive organic material
- H01B1/22—Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
Definitions
- the present invention relates to an anticorrosion paint for steel used in a building structure or civil engineering structure placed in a corrosive environment, an anticorrosion method using the anticorrosion paint, and an anticorrosion repair method.
- Hot dip galvanizing is used for exterior parts, especially roofs, etc. in building structures, and in civil engineering structures, it is used extensively in steel bridge superstructures (box girders) and support materials, as well as guardrails and road sign posts. It has been.
- hot dip galvanizing which is widely used for corrosion protection, usually takes a step of immersing in a plating tank installed in the factory, so the size of the product to be hot dip galvanized depends on the size of the tank. There was a drawback that a large size was not possible. Furthermore, since the temperature of the hot dip galvanizing tank is 430 ° C to 510 ° C, the product to be plated (steel) is deformed by heat, and correction work is required to ensure the flatness of the product after plating. was there. In the correction work, it was necessary to pay attention to cracks and damage on the plating surface.
- Inorganic zinc paints and organic zinc paints are widely used as sacrificial anticorrosion methods. Since inorganic paints are subject to adhesive strength, it is necessary to carefully control the base preparation such as blasting in order to secure the adhesive strength with the product (steel material) to be applied. When anti-corrosion performance is expected, in order to increase the film thickness, it is necessary to stably maintain a high adhesion force for a long period of time. On the other hand, in the coating using organic zinc paint with organic resin binder, the adhesion to the applied product (steel material) is better than the coating using inorganic zinc paint. It is possible to secure.
- the technology for spraying and preventing metal materials that exhibit sacrificial anode reaction requires only spraying and adhering the metal melted by the gun for spraying at a high temperature onto the product surface that has been surface-treated in advance by blasting or power tools.
- the temperature of the product does not become high, the thermal deformation of the base material can be suitably prevented, and the size of the product to be applied is limited by the size of the plating tank.
- the molten metal of aluminum or magnesium that is sprayed using a spray gun must be sprayed at a right angle to the spray surface, preferably in a narrow area where the spray gun does not enter.
- Patent Document 2 discloses a technique of a coating film formed by spraying fine particles of a metal or alloy having sacrificial corrosion resistance that has been aerosolized onto the surface of a steel material, and zinc as a metal or alloy having sacrificial corrosion resistance is disclosed. It is said that it is preferable to contain any one or more of aluminum, magnesium.
- Patent Document 2 is a technique in which fine particles of an aerosolized metal or alloy are sprayed onto the anticorrosion surface and collide with the steel surface to form a coating film.
- Spraying equipment (aerosolization chamber, classification) is used for the aerosol. Chamber, spray nozzle, gas generation chamber, film formation chamber, vacuum pump) and inert gas such as helium and nitrogen are also required. It wasn't.
- Patent Document 3 discloses a composition for powder coating (powder baking coating) in which 100 to 900 parts by weight of zinc powder is blended with 100 parts by weight of epoxy resin. This is only a powder baking paint, and it requires special equipment, and simple painting is not possible.
- the present invention is not limited by equipment such as a hot dip galvanizing tank, can prevent deformation of the base material due to high temperature heat input by hot dip galvanizing treatment, and does not use zinc.
- Conductive metal paint that can be applied easily without the need for large equipment in factory construction as well as on-site construction, by causing sacrificial anode reaction equivalent to or better than zinc, and corrosion prevention method using the conductive metal paint And it is in providing the anticorrosion repair method.
- the invention according to claim 1 is a conductive metal paint containing, as main components, a metal component that produces a sacrificial anticorrosive action on iron and an organic resin component, and contains aluminum and magnesium as the metal components.
- a conductive metal paint is provided.
- FIG. 1 schematically shows an outline of the sacrificial anticorrosion reaction in the crosscut portion of the iron base coated with aluminum and magnesium. Since the reaction rate of the sacrificial anticorrosion reaction of magnesium (Mg) is as fast as that of zinc, it elutes earlier than the iron base (FIG. 1 (a)) and forms a film such as magnesium oxide or magnesium hydroxide. Then, the iron substrate is covered (FIG. 1B). Although the iron substrate itself is slightly oxidized and eluted, a magnesium (Mg) film is formed at an early stage to cover the iron substrate, so that the elution of iron can be stopped with only a small amount.
- Mg magnesium
- Al (Al) has a slower reaction rate than magnesium (Mg), it has the property of being retained on the iron surface for a long time.
- the eluted aluminum (Al) forms a film such as aluminum oxide and protects the iron surface and magnesium (Mg) covering it for a relatively long period of time (FIG. 1 (c)). Therefore, by combining aluminum (Al) and magnesium (Mg) as a metal component, it is possible to obtain a conductive metal paint having high sacrificial anticorrosive ability and durability.
- the present invention uses an organic metal paint composed of an organic resin component as a sacrificial anticorrosion method, and compared with hot dip galvanization and metal spraying that have been used conventionally, no special equipment or equipment is required, Application with a brush, roller, spatula, or iron is possible. For this reason, it is possible to perform the anticorrosion treatment even in a narrow portion where it has been difficult to perform the conventional thermal spraying.
- a second aspect of the present invention provides the conductive metal paint according to the first aspect, wherein the metal component includes a mixed powder of aluminum powder and magnesium powder, an aluminum / magnesium alloy powder, or both in the paint.
- the metal coating described in this section may contain aluminum and magnesium as the metal components (as mixed powder), aluminum / magnesium alloy powder, and the mixed powder and alloy powder. Can be contained in a mixed state. However, it is more preferable to use mixed powder because there are advantages that individual characteristics of aluminum and magnesium are easily obtained and manufacturing costs can be suppressed.
- the particle size of the metal powder is set to 75 mesh under, preferably 100 mesh under, and more preferably 200 mesh under as long as the above production problems do not occur.
- the conductive metal paint according to the first or second aspect wherein the content ratio of aluminum and magnesium of the metal component is 5:95 to 70:30.
- the composition of the metal component contained in the conductive metal paint is preferably such that the content ratio of aluminum and magnesium is 5:95 to 70:30, and more preferably 5:95 to 50:50. preferable.
- the aluminum content is preferably 5% or more by weight.
- the content ratio of aluminum and magnesium satisfying both high anticorrosive action and anticorrosion stability is 35:65 to 15:85, more preferably 30:70. It was found that it was ⁇ 15: 85, more preferably 30:70 to 20:80.
- the conductive metal paint according to the first aspect wherein a blending ratio of the metal component and the organic resin component upon curing is 98: 2 to 80:20.
- the degree of flow of the conductive paint according to the present invention can be adjusted as desired.
- the brush coating, roller coating, or iron coating application method can be selected in accordance with the work site conditions, and the blending ratio of the metal component and the organic resin component can be changed.
- the blending ratio of the organic resin component exceeds 20 by weight, the non-conductive resin component covers most of the surface of the metal component, so that the anticorrosion reaction of the metal component is sufficiently exhibited. It is difficult to do.
- the organic resin component In order to exhibit the characteristics of the metal component of the conductive metal paint more efficiently, it is preferable to reduce the amount of the organic resin component as much as possible. However, when the organic resin component is less than 2 in weight ratio, And adhesion to the object cannot be obtained, and the function as a paint cannot be performed.
- organic resin component to be used it is possible to reduce the blending amount of the organic resin component to about 2% by using a particularly low viscosity, and more efficiently exhibit the characteristics of the metal component of the conductive metal paint. Can be made.
- the invention according to claim 5 is a construction comprising a metal component that produces a sacrificial anticorrosive action on iron and an organic resin component as main components, and a conductive metal paint containing aluminum and magnesium as the metal components.
- An anticorrosion method using a conductive metal paint characterized by being applied to a structure or a civil engineering structure.
- the invention according to claim 6 includes a conductive metal paint containing a metal component that produces a sacrificial anticorrosive action on iron and an organic resin component as main components, and aluminum and magnesium as the metal components.
- An anti-corrosion repair method using a conductive metal paint characterized in that the anti-corrosion treatment is applied to a surface of an object or civil engineering structure subjected to anti-corrosion treatment.
- a sacrificial anticorrosive action can be easily generated, and an anticorrosive effect equal to or higher than that of a rust-proof specification utilizing a sacrificial anode reaction by zinc and a high durability can be achieved. It can be obtained and can be applied to narrow parts, and it can be used for anticorrosion treatment of structures without using large-scale processes and equipment, and it can be easily performed at work in high places such as bridges. Construction is also possible.
- the conductive metal paint according to the present invention by changing the compounding ratio of the metal component and the resin component, in the actual construction, a coating method such as spray application, brush application, roller application, or ironing is selected. And it is possible to select the said mixture ratio suitably according to a usage form. Moreover, since the fluidity
- the conductive metal paint according to the present invention does not contain zinc, it is not subject to environmental impact assessment by the RoHS Directive, so no special measures are required for use and the burden of safety management is small.
- the present invention is a conductive metal paint containing a metal component that produces a sacrificial anticorrosive action on iron and an organic resin component as main components.
- This paint can also be used for corrosion protection of bare steel, steel plate, steel plate or steel material on which plating or various coating films are formed, and the primer coating applied to bare steel or steel plate. Further, a film of the conductive metal paint of the present invention can be formed. Furthermore, when it aims at anticorrosion repair, there is no limitation in the coating component of the object surface which apply
- the conductive metal paint of the present invention contains a metal component that produces a sacrificial anticorrosive action on iron and an organic resin component as main components, but the other components are blended at a weight ratio of about 5% or less when cured. If there is no change in the tendency shown in the examples described later, if the blending weight ratio is about 5% or less, other metal components, preferably a metal that is lower than iron, such as zinc or zinc-aluminum alloy, is used. Can be blended.
- aluminum and magnesium are included as metal components. These may be mixed powder, may be contained as an aluminum / magnesium alloy powder, or may be contained in a mixed state with the mixed powder and alloy powder as described above.
- an epoxy resin particularly a two-component curable epoxy resin is optimal.
- an epoxy resin used by this invention if it is conventionally used for the coating composition, there will be no restriction
- the equivalent of the epoxy resin used in the present invention is usually 600 to 2000 g / equivalent, preferably 600 to 1500 g / equivalent.
- various curing agents can be used without particular limitation as long as they are conventionally used as a curing agent in an epoxy resin-containing powder coating composition.
- examples of such curing agents include aromatic diamines such as DDM (diaminodiphenylmethane), condensates of aliphatic amines and aliphatic dicarboxylic acids, amine-based curing agents such as polyamidoamines, dicyandiamides, and imidazoles, and tetrahydroanhydrides.
- Acid anhydrides such as phthalic acid, benzophenone tetracarboxylic anhydride, trimellitic anhydride, pyromellitic anhydride, condensate of trimellitic acid ethylene glycol, acids such as decanedicarboxylic acid, isophthalic acid, acid-terminated polyester resin And hardeners, Lewis acid metal complexes such as boron trifluoride metal complexes, and phenolic compounds having an average of 1.5 or more phenolic hydroxyl groups per molecule. It is appropriate to use the curing agent so that the equivalent ratio to the epoxy resin is usually 0.2 or more.
- conventionally used pigments can be appropriately blended. Examples of such pigments include colored pigments and extender pigments.
- color pigment examples include titanium oxide, bengara, iron oxide, quinacridone, carbon black, azo compound, dioxane, selenium, phthalocyanine metal complexes, and other metal salts.
- extender pigments include barium sulfate, silicon dioxide, talc, calcium carbonate, potassium titanate whisker, aluminum borate whisker, wollastonite, aluminum oxide, asbestos, and ceramic powder.
- rust preventive pigments such as strontium chromate can be used.
- Other additives can also be blended. As such an additive, for example, a leveling agent, a pigment dispersant, a thixotropic agent, a surface tension reducing agent, or the like can be used.
- This type of pigment or additive can be blended if the blending weight ratio during curing is about 3% or less.
- adhesion force and dispersion of the metal component are suitable, for example, a urethane resin or an acrylic resin may be used, or a composite resin component composed of these may be used.
- the mixing ratio of the metal component and the organic resin component of the present invention during curing is preferably 98: 2 to 80:20 by weight.
- Test Example 1 Comparison with the prior art The conductive paint according to the present invention was manufactured, and the anticorrosion performance test was performed in comparison with the prior art. Table 1 shows the compositions and conditions of the products according to the present invention as Examples 1 to 7. In addition, the examination conditions of Comparative Examples 1 to 12 including the prior art are shown.
- the aluminum and magnesium used in Examples 1 to 5 and Comparative Examples 1 to 4 are in the form of metal powder, and both are 100 mesh under products.
- the organic resin is a two-part epoxy resin (main component: modified epoxy resin). , Curing agent: modified aliphatic polyamine).
- each paint prepared in the above procedure was used, and an anticorrosion test was conducted in the following procedure.
- an anticorrosion test a cas test method (CASS TEST: Copper-Accelerated Acid Acid Spray Spray Test) was adopted.
- the conditions of the cast test were based on JIS H 8502, and the test solution was a solution obtained by adding cupric (II) chloride dihydrate to an acetic acid acidic sodium chloride solution (NaCl 50 ⁇ 5 g / L, CuCl 2 0.205).
- test chamber temperature is 50 ⁇ 2 ° C.
- spray amount is 1.5 ⁇ 0.5 mL / h (80 cm 2 )
- the evaluation time was 92 hours.
- the test specimen was once taken out from the cast tester at each of 48 hours and 72 hours, and the surface was observed.
- the base material of the specimen used for the cast test was SPCC steel (JIS G 3141, cold rolled steel plate and steel strip), and the shape was 70 mm ⁇ 150 mm ⁇ plate thickness 1.6 mm.
- the painted surface was blasted with an abrasive material as a grit (ISO Sa3.0 base adjustment), and the Sm / Rz ratio was 4.0 or less.
- Coating on the base plate with the substrate prepared was appropriately applied as a brush or a trowel depending on the viscosity of the prepared paint, and the film thickness at the time of curing was controlled with a target of 150 to 360 ⁇ m.
- an edge width of 5 mm was cured with an insulating material from the entire back face of the test specimen and the edge face of the corrosive liquid exposed surface.
- a modified epoxy resin primer was applied with a film thickness of 100 ⁇ m or more.
- Comparative Examples 5 to 12 are an organic zinc primer (“Nippesinky 8000HB” manufactured by Nippon Paint Co., Ltd.) (Comparative Examples 5 and 6) and an organic zinc paint (Nippon Paint Co., Ltd.), which are anti-corrosion paints using a commercially available sacrificial anode reaction.
- the cast test was evaluated by judging the presence or absence of rust and paint repelling visually. The judgment criteria are as follows. A: Almost no rust is seen. ⁇ : Slight rust is observed only in a part of the cross cut portion. (Triangle
- the room temperature galvanizing agents as Comparative Examples 9 and 10 were swollen on the entire surface exposed to the corrosive liquid, and many irregularities were generated on the surface, and the sacrificial anodic reaction at the cross-cut portion could not be confirmed. This is probably because the corrosive liquid permeated the coating and the iron substrate under the coating was corroded.
- the zinc aluminum sprayed specimens as Comparative Examples 11 and 12 also bulge over the entire surface exposed to the corrosive liquid as in the case of the normal temperature, causing many irregularities on the surface, and performing a sacrificial anodic reaction at the crosscut portion. Although it was not in a state that could be confirmed, it seems that this was because the corrosive liquid permeated and the iron substrate under the coating was corroded because no sealing treatment was applied to the sprayed coating. In any case, it can be said that these comparative examples did not clear the cast test conditions.
- FIG. 2 shows Example 4 that showed good anticorrosion properties among the specimens subjected to the present cast test (mixed with 50 wt% aluminum powder and 50 wt% magnesium powder, and the mixing ratio with the resin component was 85.5 wt%) 14.5 wt%) and Comparative Example 6 (organic zinc primer) after 92 hours.
- the particle size of the metal powder used for the present Example and the comparative example used the 100 mesh under goods, what is necessary is just to be able to disperse
- Test Example 2 Examination of the content ratio of aluminum and magnesium in the metal component
- 10 kinds of mixed metal powders having different metal content ratios were prepared, A paint containing 15% or 10% of a resin component was prepared.
- Aluminum and magnesium were both in the form of metal powder, and 100-mesh under products were used.
- As the organic resin a two-component epoxy resin (main agent: modified epoxy resin, curing agent: modified aliphatic polyamine) was used.
- Table 3 shows the metal component content ratio (weight ratio) and organic resin component blend ratio (cured weight ratio) in Examples 8 to 21 and Comparative Examples 13 to 18.
- the paints of Examples 8 to 21 and Comparative Examples 13 to 18 were applied to the blasted specimens similar to Test Example 1 with a brush or a trowel so that the film thickness upon curing was about 100 to 500 ⁇ m. . Further, an edge width of 5 mm was cured with an insulating material (modified epoxy resin primer: film thickness of 100 ⁇ m or more) from the entire back surface of the test specimen and the edge surface of the corrosive liquid exposed surface. Further, a crosscut (JIS H8502: 1999) was given to the coating surface and used for the test.
- modified epoxy resin primer film thickness of 100 ⁇ m or more
- Examples 8, 9, 12 to 14, 15, 16, 19 to 21 and Comparative Examples 13 to 18 and Cass Test Method Examples 8 to 12, 15 to 19, and Comparative Example 13 , 14, 16 and 17 were subjected to an anticorrosion test by the combined cycle test method.
- an anticorrosion test by the combined cycle test method.
- the evaluation time was set to 360 hours, and the test specimen was once taken out from the cast test machine and observed on the surface for 24 hours and 120 hours as confirmation of the progress of the test specimen surface.
- the test was performed under the same conditions as in Test Example 1 except for the evaluation time.
- the cast test is frequently used for the evaluation of hot dip galvanizing, but for the hot dip galvanizing evaluation, a test of up to 96 hours is recommended. Generally, the test object is rusted and the coating peels off during the 96 hour test. If there is no such thing, it is evaluated as having good anticorrosive action.
- the cast test in this study can be said to be a test with a higher load than the evaluation of hot dip galvanizing.
- the combined cycle test method was performed by repeating the cycle of Table 2 in accordance with JIS H 8502: 1999.
- the salt water used was prepared by dissolving sodium chloride at 50 ⁇ 5 g / L per liter of the test solution and adjusting the pH to 6.5.
- the evaluation time of the combined cycle test was 360 hours (45 cycles), and surface observation was also performed when 24 hours (3 cycles) and 120 hours (15 cycles) had elapsed.
- the evaluation in the cast test and the combined cycle test was performed by visually determining the presence or absence of rust of the test specimen, paint delamination, and the like.
- the determination criteria are the same as in [Test Example 1].
- Table 3 shows the results of the cast test and the combined cycle test of Examples 8 to 21 and Comparative Examples 13 to 18. Moreover, the photograph of the crosscut part of each test body of the cast test 120 hours is shown in FIG.3 and FIG.4, and the photograph of the crosscut part of each test body of the combined cycle test 360 hours is shown in FIG.5 and FIG.6.
- the content ratio of aluminum and magnesium in the metal component of the conductive metal paint is a balanced ratio that can sufficiently exhibit the above-described characteristics of both metals. From this study, it was revealed that a suitable content ratio of aluminum and magnesium is 25:75 to 15:85.
- Test Example 3 Examination of blending ratio of organic resin component
- the content ratio of aluminum and magnesium in the metal component was set to 25:75.
- the compounding ratio of the metal component and the organic resin component is 90:10 (Example 22), 85:15 (Example 23), 80:20 (Example 24), 75:25 (Comparative Example 19) by dry weight, A conductive metal paint containing 10% (15, 20, 25, 30% was prepared.
- the paints of Examples 22 to 24 and Comparative Examples 19 and 20 were cured to the same blasted specimens as in Test Example 1.
- the film was coated with a brush or a trowel so that the film thickness was 300 ⁇ 50 ⁇ m.
- the surface resistivity of each specimen was measured using a parallel plate electrode method (HIOKI's resistance meter 3541). Table 4 shows the surface resistivity of each specimen.
- the surface resistivity of Examples 22 to 24 was as low as 60 to 70 ⁇ , while Comparative Examples 19 and 20 exhibited high surface resistivity so that measurement was impossible. From the results of this study, it has been clarified that the blending ratio of the organic resin component is preferably lower than 20% in order for the metal paint to exhibit sufficient conductivity.
- the anticorrosion performance of the conductive metal coating depends on the film thickness of the coating, it has been found from the experimental results that 150 ⁇ m or more, particularly 200 ⁇ m or more, further 300 ⁇ m or more is desirable. Usually, it is set to 1500 ⁇ m or less.
- the above uses a two-component curable epoxy as the organic resin, but even if a commercially available urethane resin or acrylic resin is used, almost the same result was obtained although it was slightly inferior in durability.
- the conductive paint according to the present invention can be used as an anticorrosion paint for steel materials used in a building structure or civil engineering structure placed in a corrosive environment, and also requires all anticorrosion treatments for vehicles, steel materials, etc. It can be used in fields and objects.
Abstract
Description
しかし、特許文献2はエアゾル化した金属または合金の微粒子を防食表面へ吹付けて鋼材表面に衝突させて被覆膜を形成させる技術であり、エアゾル用に吹付用の設備(エアゾル化室、分級室、噴射ノズル、ガス発生室、成膜室、真空ポンプ)が必要であり、さらにはヘリウム、窒素などの不活性ガスも必要であり、やはり、現場施工で容易に被覆膜を形成できるものではなかった。
請求項1記載の発明は、鉄に対して犠牲防食作用を生じる金属成分と有機系樹脂成分とを主成分として含む導電性金属塗料であって、前記金属成分としてアルミニウムとマグネシウムを含むことを特徴とする導電性金属塗料を提供する。
従来、犠牲防食作用を生じる金属としては、高い犠牲防食反応を示す亜鉛が広く使用されていたが、原料鉱に含まれる鉛、カドミウムによる環境汚染の問題、防食性能の耐久性の問題などがあった。本発明は、亜鉛を使用せず、アルミニウムとマグネシウムの両者を使用することで、亜鉛に匹敵する犠牲防食反応を示し、かつ防食性能の高い耐久性を示すことを知見し、これを利用した犠牲防食塗料を提供するものである。
請求項2記載の発明は、前記金属成分として、アルミニウム粉とマグネシウム粉の混合粉、アルミニウム/マグネシウム合金粉、または両方を塗料中に含む請求項1記載の導電性金属塗料を提供する。
本項記載の金属塗料は、前記金属成分として、アルミニウム、マグネシウムをそれぞれの粉体として(混合粉として)含有することも、アルミニウム/マグネシウム合金粉として含有することも、また前記混合粉と合金粉とを混合した状態で含有することもできる。しかし、アルミニウム、マグネシウムの個々の特性が出やすい、製造コストを抑えられる、という利点があることから、混合粉とすることがより好ましい。
請求項3記載の発明は、前記金属成分のアルミニウムとマグネシウムの含有比率が重量比で5:95~70:30である請求項1または2に記載の導電性金属塗料を提供する。
導電性金属塗料中に含まれる金属成分の組成は、アルミニウムとマグネシウムの含有比率を重量比で5:95~70:30とすることが好ましく、更に5:95~50:50とすることがより好ましい。前述のように、マグネシウムは反応性が高く、早期に溶出するのに対して、アルミニウムは比較的安定性が高いため、マグネシウムをより多く配合することで、マグネシウムの高い防食作用を長時間維持することができる。加えて、アルミニウムの有する長期安定性をも発揮するために、アルミニウムの含有量は、重量比で5%以上配合することが好ましい。
請求項4記載の発明は、前記金属成分と有機系樹脂成分との硬化時の配合比率が重量比で98:2~80:20である請求項1記載の導電性金属塗料を提供する。
金属成分と有機系樹脂成分との配合比を重量比で98:2~80:20として、この範囲で適宜調整することにより、本発明に係る導電性塗料の流動の程度を所望に調整できる。使用する塗料の流動性により、作業現場状況にあわせて、刷毛塗り、ローラー塗り又はコテ塗り塗布方法を選択し、金属成分と有機系樹脂成分との配合比を変更することができる。有機系樹脂成分の配合比が重量比で20を超えると、金属成分の表面の大部分を非導電性の樹脂成分が被覆してしまい、金属成分の防食反応の反応性を十分に発揮することができ難い。導電性金属塗料の金属成分の特性をより効率よく発揮させるためには、有機系樹脂成分の配合は可能な限り少なくすることが好ましいが、有機系樹脂成分が重量比で2未満となると、流動性、目的物への付着性は得られなくなり、塗料としての機能を果たさなくなってしまう。
請求項5記載の発明は、鉄に対して犠牲防食作用を生じる金属成分と有機系樹脂成分とを主成分として含み、前記金属成分としてアルミニウムとマグネシウムを含む導電性金属塗料を、鉄からなる建築構造物または土木構造物に塗布することを特徴とする導電性金属塗料による防食方法を提供する。
アルミニウム及びマグネシウムを犠牲防食金属として使用する導電性金属塗料を塗布する防食方法を用いることで、従来溶融亜鉛めっきが不可能であった、巨大な固定建造物などに対しても直接防食処理を施すことができる。また、従来金属溶射が困難であった、狭小な部位や、橋梁等の高所の現場作業においても、容易に防食処理を施すことが可能となった。
請求項6記載の発明は、鉄に対して犠牲防食作用を生じる金属成分と有機系樹脂成分とを主成分として含み、前記金属成分としてアルミニウムとマグネシウムを含む導電性金属塗料を、既存の建築構造物または土木構造物の防食処理の施された表面に塗布することを特徴とする導電性金属塗料による防食補修方法を提供する。
アルミニウム及びマグネシウムを犠牲防食金属として使用する導電性金属塗料を塗布する方法を用いることで、固定された建造物などで、すでに防食処理が施された部位について、容易に補修作業を行うことが可能である。
本発明の導電性金属塗料は、鉄に対して犠牲防食作用を生じる金属成分と有機系樹脂成分とを主成分として含むが、他の成分を硬化時の配合重量比率で、5%程度以下であれば後述の実施例で示す傾向になんら変化はないから、配合重量比率で、5%程度以下であれば、他の金属成分、好ましくは鉄より卑なる金属、たとえば亜鉛又は亜鉛・アルミニウム合金を配合することができる。
本発明においては、金属成分としてアルミニウムとマグネシウムを含む。これらは混合粉でもよいし、アルミニウム/マグネシウム合金粉として含有することも、また前記混合粉と合金粉とを混合した状態で含有することもできることは既述のとおりである。
アルミニウムとマグネシウムの含有比率を重量比の好適範囲についても既述のとおりである。
本発明における有機系樹脂成分としては、エポキシ系樹脂、とりわけ二液硬化性エポキシ系樹脂が最適である。本発明で用いるエポキシ樹脂としては、従来より、塗料組成物に使用されているものであれば、特に制限なく、各種のエポキシ樹脂を使用することができる。このようなエポキシ樹脂としては、例えば、ビスフェノールAや、ビスフェノールF、ビスフェノールS、ノボラック系のグリシジルエーテル型、グリシジルエステル型、グリシジルアミン型、ジシクロペンタジエン骨格型、ビフェノール型等が挙げられる。コスト面と性能のバランスからビスフェノールAや、フェノールF、ノボラック系が好適である。特に溶融粘度の低さからビスフェノールAを主体とする物が好適である。
本発明で使用するエポキシ樹脂の当量は、通常、600~2000g/当量、好ましくは、600~1500g/当量であることが適当である。硬化剤としては、従来より、エポキシ樹脂含有粉体塗料組成物における硬化剤として使用されているものであれば、特に制限されることなく、各種の硬化剤を使用することができる。このような硬化剤としては、例えば、DDM(ジアミノジフェニルメタン)のような芳香族ジアミンや、脂肪族アミンと脂肪族ジカルボン酸の縮合物、ポリアミドアミン、ジシアンジアミド、イミダゾール等のアミン系硬化剤、無水テトラヒドロフタル酸、無水ベンゾフェノンテトラカルボン酸、無水トリメリット酸、無水ピロメリット酸、トリメリット酸エチレングリコールの縮合物の様な酸無水物類、デカンジカルボン酸、イソフタル酸、酸末端ポリエステル樹脂の様な酸系硬化剤、三弗化硼素金属錯体等のルイス酸金属錯体類、平均で1分子当たりフェノール性水酸基を1.5 個以上有するフェノール系化合物等が挙げられる。硬化剤は、エポキシ樹脂に対して、通常、当量比で、0.2以上となるように使用することが適当である。
本発明の塗料には、従来より使用されている顔料を適宜配合することができる。このような顔料としては、例えば、着色顔料や、体質顔料等を挙げることができる。着色顔料としては、例えば、酸化チタンや、ベンガラ、酸化鉄、キナクリドン、カーボンブラック、アゾ化合物、ジオキサン、スレン、フタロシアニンの金属錯体、その他金属塩を主とする物が列挙できる。体質顔料としては、例えば、硫酸バリウムや、二酸化珪素、タルク、炭酸カルシウム、チタン酸カリウムウィスカ、ホウ酸アルミニウムウィスカ、ウォラストナイト、酸化アルミニウム、アスベスト、セラミックパウダー等が列挙できる。また、ストロンチウムクロメート等の防錆顔料も使用可能である。その他の添加剤も配合することができる。そのような添加剤としては、例えば、レベリング剤や、顔料分散剤、チクソトロピック性付与剤、表面張力低下剤などが使用できる。この種の顔料や添加剤は、硬化時の配合重量比率で、3%程度以下であれば配合できる。
本発明においてエポキシ樹脂のほか、付着力、金属成分の分散が好適であれば、例えばウレタン樹脂、アクリル樹脂を用いてもよく、またこれらからなる複合系樹脂成分であっても良い。
本発明の前記金属成分と前記有機系樹脂成分との硬化時の配合比率としては、重量比で98:2~80:20が望ましい。
本発明に係る導電性塗料を製造し、従来技術と比較した防食性能試験を行った。表1に、実施例1~7として、本発明に係る実施品の組成、条件を示した。併せて、従来技術を含めた比較例1~12の検討条件を示した。
実施例1~5,比較例1~4に用いたアルミニウムとマグネシウムは金属粉の状態で、ともに100メッシュアンダー品を使用し、有機系樹脂としては二液性エポキシ系樹脂(主剤:変性エポキシ樹脂、硬化剤:変性脂肪族ポリアミン)を使用した。前記アルミニウム粉とマグネシウム粉の混合比率を重量比率で、50:50(実施例1~4)、70:30(実施例5)、95:5(比較例1~4)の3段階とした金属成分を作成し、該金属成分と樹脂成分との混合比率を硬化時の重量比率で95:5から85:15とした。
◎:錆がほとんど見られない。
○:クロスカット部の一部にのみ軽微な錆が見られる。
△:クロスカット部に全体的に軽微な錆が見られる。
×:クロスカット部に著しい錆が見られる、またはクロスカット部とクロスカット部以外に渡り、全体的に錆が見られる。
金属成分におけるアルミニウムとマグネシウムの好適な含有比率を検討するため、金属の含有比率の異なる10種類の金属混合粉を用意し、有機系樹脂成分を15%または10%含む塗料を調製した。アルミニウムとマグネシウムは金属粉の状態で、ともに100メッシュアンダー品を使用し、有機系樹脂としては二液性エポキシ系樹脂(主剤:変性エポキシ樹脂、硬化剤:変性脂肪族ポリアミン)を使用した。実施例8~21、比較例13~18の金属成分の含有比率(重量比率)、有機系樹脂成分の配合比率(硬化時重量比率)は表3に示すとおりである。
導電性金属塗料中の有機系樹脂成分の好適な配合比率を検討するため、金属成分中のアルミニウムとマグネシウムの含有比率を25:75として、金属成分と有機系樹脂成分の配合比率を乾燥重量で90:10(実施例22)、85:15(実施例23)、80:20(実施例24)、75:25(比較例19)、10%(,15,20,25,30%含む導電性金属塗料を調製した。実施例22~24,比較例19,20の塗料について、試験例1と同様のブラスト処理した試験体に硬化時の膜厚が300±50μmとなるように、刷毛塗りまたはコテ塗りで塗装した。
本検討の結果より、金属塗料が充分な導電性を奏するためには、有機系樹脂成分の配合比率を20%より低くすることが好ましいことが明らかとなった。
導電性金属塗料の防食性能は、被膜の膜厚にも依存するが、実験の結果から、150μm以上、特に200μm以上、さらには300μm以上が望ましいことを知見している。通常は、1500μm以下とされる。
他方、上記は有機系樹脂として二液硬化性エポキシを使用したが、市販のウレタン樹脂又はアクリル樹脂を使用したとしても、やや耐久性に劣るもののほぼ同様の結果を得た。
Claims (6)
- 鉄に対して犠牲防食作用を生じる金属成分と有機系樹脂成分とを主成分として含む導電性金属塗料であって、前記金属成分としてアルミニウムとマグネシウムを含むことを特徴とする導電性金属塗料。
- 前記金属成分として、アルミニウム粉とマグネシウム粉の混合粉、アルミニウム/マグネシウム合金粉、または両方を塗料中に含む請求項1記載の導電性金属塗料。
- 前記金属成分のアルミニウムとマグネシウムの含有比率が重量比で5:95~70:30である請求項1または2に記載の導電性金属塗料。
- 前記金属成分と有機系樹脂成分との硬化時の配合比率が重量比で98:2~80:20である請求項1記載の導電性金属塗料。
- 鉄に対して犠牲防食作用を生じる金属成分と有機系樹脂成分とを主成分として含み、前記金属成分としてアルミニウムとマグネシウムを含む導電性金属塗料を、鉄からなる建築構造物または土木構造物に塗布することを特徴とする導電性金属塗料による防食方法。
- 鉄に対して犠牲防食作用を生じる金属成分と有機系樹脂成分とを主成分として含み、前記金属成分としてアルミニウムとマグネシウムを含む導電性金属塗料を、既存の建築構造物または土木構造物の防食処理の施された表面に塗布することを特徴とする導電性金属塗料による防食補修方法。
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KR1020117027218A KR101722793B1 (ko) | 2009-04-22 | 2010-04-21 | 도전성 금속도료 및 도전성 금속도료에 의한 방식방법 및 방식보수방법 |
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CN103265868A (zh) * | 2013-05-20 | 2013-08-28 | 邢士波 | 一种海洋重防腐环氧富铝镁纳米涂料及其制备方法 |
KR101580682B1 (ko) | 2014-07-28 | 2015-12-28 | 주식회사 혁성 | 상수원 수도 구조물의 친환경 방식 및 방오 코팅방법 및 이러한 방법으로 제조된 상수원 수도 구조물 |
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CN112787258B (zh) * | 2020-12-31 | 2023-02-03 | 广东电网有限责任公司韶关供电局 | 一种配电箱的修复方法 |
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EP2423268A1 (en) | 2012-02-29 |
EP2423268A4 (en) | 2012-10-31 |
KR101722793B1 (ko) | 2017-04-03 |
KR20120013387A (ko) | 2012-02-14 |
US20120114845A1 (en) | 2012-05-10 |
JPWO2010123028A1 (ja) | 2012-10-25 |
US9290670B2 (en) | 2016-03-22 |
JP5698122B2 (ja) | 2015-04-08 |
CN102414280A (zh) | 2012-04-11 |
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