WO2021168180A1 - Revêtements à base de silicate pulvérisables et leurs procédés de fabrication et d'application - Google Patents

Revêtements à base de silicate pulvérisables et leurs procédés de fabrication et d'application Download PDF

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Publication number
WO2021168180A1
WO2021168180A1 PCT/US2021/018676 US2021018676W WO2021168180A1 WO 2021168180 A1 WO2021168180 A1 WO 2021168180A1 US 2021018676 W US2021018676 W US 2021018676W WO 2021168180 A1 WO2021168180 A1 WO 2021168180A1
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WIPO (PCT)
Prior art keywords
percent
weight
powder
component
silicate
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PCT/US2021/018676
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English (en)
Inventor
Dr. Arun WAGH
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Ceramicoat International Limited
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Priority claimed from US16/795,094 external-priority patent/US11565973B2/en
Application filed by Ceramicoat International Limited filed Critical Ceramicoat International Limited
Publication of WO2021168180A1 publication Critical patent/WO2021168180A1/fr

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Classifications

    • 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
    • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
    • C03C8/14—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
    • C04B28/346—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders the phosphate binder being present in the starting composition as a mixture of free acid and one or more phosphates
    • C04B28/348—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders the phosphate binder being present in the starting composition as a mixture of free acid and one or more phosphates the starting mixture also containing one or more reactive oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C04B2111/00525—Coating or impregnation materials for metallic surfaces

Definitions

  • the present invention relates generally to silicate-based coatings and to methods to make and apply same.
  • the silicate-coatings of the present invention are formed from a two part mixture of phosphate-based component and a glass-based component.
  • the silicate-based coatings of the present invention are free from any organic materials.
  • VOCs volatile organic compounds
  • the present invention relates generally to silicate-based coatings and to methods to make and apply same.
  • the silicate-coatings of the present invention are formed from a two part mixture of phosphate-based component and a glass-based component.
  • the silicate-based coatings of the present invention are free from any organic materials.
  • the present invention comprises a silicate-based coating composition
  • a silicate-based coating composition comprising: Part (A), wherein Part (A) is an acidic phosphate-based material selected from one or more of Part (Al) and/or Part (A2); and Part (B), wherein Part (B) is a glass powder/metal oxide mixture selected from one or more of Part (Bl) and/or Part (B2), wherein Part (A) is combined with Part (B) at a ratio of Part (A) to Part (B) of about 1 : 0.5 to about 1:3, wherein Part (Al) comprises: (Ala) from about 58 percent by weight to about 78 percent by weight of at least one alkali-acid phosphate or an equivalent thereof; (Alb) from about 1 percent by weight to about 5 percent by weight of phosphoric acid or an equivalent thereof; and (Ale) from about 17 percent by weight to about 37 percent by weight of water, wherein Part (A2) comprises: (A2a) from about 5 percent by weight to about
  • the present invention comprises an acidic phosphate-based material comprising one or both of Part (Al) and/or Part (A2), wherein Part (Al) comprises: (Ala) from about 58 percent by weight to about 78 percent by weight of at least one alkali- acid phosphate or an equivalent thereof; (Alb) from about 1 percent by weight to about 5 percent by weight of phosphoric acid or an equivalent thereof; and (Ale) from about 17 percent by weight to about 37 percent by weight of water, and wherein Part (A2) comprises: (A2a) from about 5 percent by weight to about 17 percent by weight of at least one metal compound, metal oxide or an equivalent thereof; (A2b) from about 44 percent by weight to about 64 percent by weight of phosphoric acid or an equivalent thereof; and (A2c) from about 24 percent by weight to about 44 percent by weight of water.
  • the present invention comprises a glass powder/metal oxide mixture comprising one or both of Part (Bl) and/or Part (B2), wherein Part (Bl) comprises: (Bla) from about 30 percent by weight to about 50 percent by weight of at least one silica-based glass powder or equivalent thereof; (Bib) from about 12 percent by weight to about 32 percent by weight of at least one metal oxide or an equivalent thereof; and (Blc) from about 23 percent by weight to about 43 percent by weight of water, and wherein Part (B2) comprises: (B2a) from about 12 percent by weight to about 32 percent by weight of at least one silica-based glass powder or equivalent thereof; (B2b) from about 30 percent by weight to about 50 percent by weight of at least one metal oxide or an equivalent thereof; and (B2c) from about 25 percent by weight to about 45 percent by weight of water.
  • Part (Bl) comprises: (Bla) from about 30 percent by weight to about 50 percent by weight of at least one silica-based glass powder or equivalent thereof; (Bib) from about
  • the present invention comprises a silica-based glass powder comprising: from about 23 percent by weight to about 43 percent by weight of silicon dioxide powder or an equivalent thereof; from about 23 percent by weight to about 43 percent by weight of at least one form of aluminum oxide powder; and from about 18 percent by weight to about 38 percent by weight of calcium fluoride powder; and from about 1 percent by weight to about 11 percent by weight of sodium hexafluoroaluminate powder, wherein the above components and/or their equivalents are mixed together, vitrified and then pulverized into a powder to form the silica-based glass powder.
  • the present invention relates generally to silicate-based coatings and to methods to make and apply same.
  • the silicate-coatings of the present invention are formed from a two part mixture of phosphate-based component and a glass- based component.
  • the silicate-based coatings of the present invention are free from any organic materials.
  • the words “example” and “exemplary” mean an instance, or illustration.
  • the words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment.
  • the word “or” is intended to be inclusive rather an exclusive, unless context suggests otherwise.
  • the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C).
  • the articles “a” and “an” are generally intended to mean “one or more” unless context suggests otherwise.
  • the coatings of the present invention are formed from the combination of a two part formulation where Part (A) is selected from an acidic phosphate- based material and Part (B) is a combination of a glass powder with one or more metal oxides.
  • the coatings of the present invention are formed from the combination of a two part formulation selected from Part (Al) and/or Part (A2) in combination with Part (Bl) and/or Part (B2).
  • the coatings of the present invention can be formed by any combination of Part (Al) with Part (Bl), Part (A2) with Part (B2), Part (A2) with Part (Bl), or Part (A2) with Part (B2) as will be detailed below. The details regarding the specific formations of Parts (Al), (A2), (Bl) and (B2) will also be described in detail below.
  • both Part (Al) and Part (A2) are acidic in nature and have pH values below about 5, below about 4.5, below about 4, below about 3.5, or even about 3.
  • both Part (Bl) and (B2) are alkali in nature and have pH values above about 7.5, above about 8, above about 8.5, or even about 9.
  • both Part (Bl) and Part (B2) can be formed to have a essentially neutral pH of between about 6.5 and 7.5.
  • Part (Al) is in one embodiment formed from a combination of: (Ala) at least one alkali-acid phosphate (e.g., LiH2P04, NaH2P04 and/or K ⁇ 2R04) or an equivalent thereof; (Alb) phosphoric acid (H3P04) or an equivalent thereof; and (Ale) water.
  • a combination of alkali phosphates can be utilized in combination with component (Ala) or even in place of component (Ala) - the at least one alkali-acid phosphate - so long as the compound in question has at least one acid-phosphate therein.
  • suitable alkali phosphates and/or alkali-acid phosphates include, but are not limited to, monolithium phosphate (LiH2P04), dilithium phosphate (Li2H2P04), monopotassium phosphate (K ⁇ 2R04), dipotassium phosphate (K2HP04), monosodium phosphate (NaH2P04), disodium phosphate (Na2HP04), monosodium diphosphate (NaH3P207), disodium diphosphate ( a 2 H 2 P 207 ), trisodium diphosphate (Na3HP207), tetrasodium diphosphate (Na4P207), or mixtures of any two or more, three or more, four or more, or even five or more thereof.
  • the above phosphate compounds are shown solely as anhydrous compounds they are not restricted to such. Rather, any hydrated forms of such compounds are also covered thereby regardless of the number of bound water molecules contained in their hydrated
  • component (Alb) of Part (Al) - the phosphoric acid (H3P04) - can be replaced by a mixture of one or more other phosphoric acids or phosphoric acid anhydrides including, but not limited to, one or more of orthophosphoric acid (H3P04) (also referred to herein as just phosphoric acid), pyrophosphoric acid (H4P207), tripolyphosphoric acid p5 P 30io ), tetrapolyphosphoric acid (H6P4013), trimetaphosphoric acid (H3P309), phosphoric anhydride (P40io) and/or pyrophosphoric acid (H4P207).
  • orthophosphoric acid H3P04
  • H4P207 also referred to herein as just phosphoric acid
  • tripolyphosphoric acid p5 P 30io tripolyphosphoric acid p5 P 30io
  • tetrapolyphosphoric acid H6P4013
  • trimetaphosphoric acid H3P309
  • component (Alb) of Part (Al) - the phosphoric acid (H3P04) - can be replaced by a mixture of two or more of the above phosphoric acids or phosphoric anhydrides, three or more of the above phosphoric acids or phosphoric anhydrides, four or more of the above phosphoric acids or phosphoric anhydrides, or even five or more of the above phosphoric acids or phosphoric anhydrides.
  • component (Alb) is phosphoric acid (H3P04)
  • concentration of the acid used for component (Alb) is 85 percent by weight.
  • various other concentrations of acids can be used for component (Alb) but the amount of component (Alb) in Part (Al), as detailed herein, is based on the use of phosphoric acid (H3P04) with a concentration of 85 percent by weight. Accordingly, should a different compound be used for component (Alb), the amount thereof should be adjusted to yield the same amount of acid as if phosphoric acid (H3P04) with a concentration of 85 percent by weight were used to provide the desired weight percentage of component (Alb) as detailed below.
  • Part (Al) is an inorganic composition formed from components (Ala), (Alb) and (Ale), where Part (Al) has less than about 7.5 percent by weight carbon and/or other organic compounds, has less than about 5 percent by weight carbon and/or other organic compounds, has less than about 2.5 percent by weight carbon and/or other organic compounds, has less than about 1 percent by weight carbon and/or other organic compounds, has less than about 0.5 percent by weight carbon and/or other organic compounds, has less than about 0.1 percent by weight carbon and/or other organic compounds, or is even free of (that is has zero percent by weight) carbon and/or other organic compounds.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (Al) can further optionally include one or more additional additives such as one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray-dried granules), or mixtures of any two or more, three or more, four or more, or even five or more thereof.
  • additional additives such as one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more r
  • additives may be organic in nature. Such additives are utilized to impart various desired properties to the mixture that forms the basis of Part (Al) of the present invention and permits Part (Al) to have improved shelf-life, improved rheological properties, improved mixability and/or spray ability, etc.
  • Part (Al) will include a minor amount of organic material.
  • minor amount it is meant that Part (Al) will have less than about 7.5 percent by weight carbon and/or other organic compounds, will have less than about 7 percent by weight carbon and/or other organic compounds, will have less than about 6.5 percent by weight carbon and/or other organic compounds, will have less than about 6 percent by weight carbon and/or other organic compounds, will have less than about 5.5 percent by weight carbon and/or other organic compounds, will have less than about 5 percent by weight carbon and/or other organic compounds, will have less than about 4.5 percent by weight carbon and/or other organic compounds, will have less than about 4 percent by weight carbon and/or other organic compounds, will have less than about 3.5 percent by weight carbon and/or other organic compounds, will have less than about 3.
  • percent by weight carbon and/or other organic compounds will have less than about 2.5 percent by weight carbon and/or other organic compounds, will have less than about 1 percent by weight carbon and/or other organic compounds, or will even have less than about 0.5 percent by weight carbon and/or other organic compounds.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (Al) is formed from about 58 percent by weight to about 78 percent by weight component (Ala), from about 1 percent by weight to about 5 percent by weight component (Alb) and from about 17 percent by weight to about 37 percent by weight component (Ale).
  • Part (Al) can further include one or more additional additives such as one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan granulation, seed coatings, extruded and/or spray-dried granules), or mixtures of any two or more, three or more, four or more, or even five or more thereof are present in total, or even individually, at a range of about 0.1 percent by weight to about 3 percent by weight.
  • additional additives such as one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers
  • Part (Al) further includes one or more additional additives such as one or more clay-based rheology modifiers (e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF) at a range of about 0.1 percent by weight to about 2.5 percent by weight and/or one or more lignin compounds such as a calcium lignosulphonate at a range of about 0.1 percent by weight to about 2.5 percent by weight.
  • clay-based rheology modifiers e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF
  • lignin compounds such as a calcium lignosulphonate
  • Part (Al) is formed from about 60 percent by weight to about 76 percent by weight component (Ala), from about 62 percent by weight to about 74 percent by weight component (Ala), from about 64 percent by weight to about 72 percent by weight component (Ala), from about 66 percent by weight to about 70 percent by weight component (Ala), or even about 68 percent by weight component (Ala).
  • Al is formed from about 60 percent by weight to about 76 percent by weight component (Ala), from about 62 percent by weight to about 74 percent by weight component (Ala), from about 64 percent by weight to about 72 percent by weight component (Ala), from about 66 percent by weight to about 70 percent by weight component (Ala), or even about 68 percent by weight component (Ala).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (Al) is formed from about 1.5 percent by weight to about 4.5 percent by weight component (Alb), from about 2 percent by weight to about 4 percent by weight component (Alb), from about 2.5 percent by weight to about 3.5 percent by weight component (Alb), or even about 3 percent by weight component (Alb).
  • Part (Al) is formed from about 19 percent by weight to about 35 percent by weight component (Ale), from about 21 percent by weight to about 33 percent by weight component (Ale), from about 23 percent by weight to about 31 percent by weight component (Ale), from about 25 percent by weight to about 29 percent by weight component (Ale), or even about 27 percent by weight component (Ale).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the one or more additional additives such as the one or more clay-based rheology modifiers (e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF) are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • the one or more clay-based rheology modifiers e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF
  • the one or more additional additives such as the one or more lignin compounds such as a calcium lignosulphonate are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (Al) is formed by the following procedure: Step (i) pour the requisite and/or desired amount of water (component (Ale)) - in this case 4.2 pounds - into a mixing bowl (component (Ale) - tap water or any other suitable type of water such as distilled water will suffice); Step (ii) start the mixer; Step (iii) as the mixer is mixing, add the requisite and/or desired amount - in this case 0.5 pounds - of component (Alb) (the 85 percent by weight phosphoric acid (H3P04) or any suitable analog thereof as defined above).
  • component (Alb) the 85 percent by weight phosphoric acid (H3P04) or any suitable analog thereof as defined above.
  • Step (iv) keep mixing and gradually start adding the requisite and/or desired amount - in this case 10.5 pounds - of component (Ala) (generally this component is in the form of a powder), initially the powder will dissolve, but as one continues mixing in more of the powder of component (Ala), it will not dissolve and a slurry will form.
  • component (Ala) generally this component is in the form of a powder
  • Step (iv) if so desired, add any one or more optional additives described above (e.g., the one or more clay-based rheology modifiers and/or one or more lignin compounds such as a calcium lignosulphonate) at any desired amount - in this case 0.15 pounds of each of the Attagel and Norlig A detailed above are added to Part (Al).
  • any optional step is complete, Part (Al) can be placed in a suitable shipping container for use at a later date as will be described below. Additionally, once the formulation of Part (Al) is complete, Part (Al) can be placed in a suitable shipping container for use at a later date as will be described below, with one or more of Part (Bl) and/or Part (B2).
  • Part (A2) is in one embodiment formed from a combination of: (A2a) at least one metal compound, metal oxide or an equivalent thereof; (A2b) phosphoric acid (H3P04) or an equivalent thereof; and (A2c) water. In another embodiment, mixtures of any two or more, three or more, or even four or more metals, metal oxides, or equivalents thereof can be utilized in place of component (A2a).
  • component (A2a) is formed from one or more metal powders or one or more metal oxide powders selected from one or more aluminum metal powders, one or more aluminum oxide powders, one or more zinc metal powders, one or more zinc oxide powders, one or more iron metal powders, one or more iron oxide powders, one or more titanium metal powders, one or more titanium oxide powders, one or more magnesium metal powders, one or more magnesium oxide powders, one or more copper metal powders, one or more copper oxide powders, one or more manganese metal powders, one or more manganese oxide powders, or any mixture of two or more thereof, or any mixture of three or more thereof, or any mixture of four or more thereof, or even any mixture of five or more thereof.
  • component (A2a) is formed from a combination of one or more aluminum metal powders and/or one or more aluminum oxide powders in combination with one or more zinc metal powders and/or one or more zinc oxide powders in further combination with one or more magnesium metal powders and/or one or more magnesium oxide powders.
  • any of the additional metals and/or metal oxide compounds not in the three metal mixture of aluminum, zinc and magnesium can optionally be added as additional compounds at similar amounts as specified below for the one or more additional additives such as, for example, the rheology modifiers and/or the one or more lignin compounds.
  • component (A2a) is itself formed from a mixture of from about 21 percent by weight to about 41 aluminum metal powder, from about 54 percent by weight to about 74 percent by weight zinc metal powder and from about 1 percent by weight to about 9 percent by weight magnesium metal powder.
  • metal oxide powders are utilized in place of the above mentioned aluminum, zinc and magnesium metal powders, such oxide powders can be utilized the ranges stated above for each respective similar metal powder.
  • the total amount of each part of component (A2a) may individually total more than 100 weight percent when each component is taken individually and totaled using the broadest amounts disclosed herein, one of skill in the art will realize that this is not the case. Rather, each individual part of component (A2a) can be varied within any stated range as desired in order to achieve a total weight percent of 100.
  • the aluminum portion of component (A2a) is formed from about 23 percent by weight to about 39 percent by weight aluminum metal powder or aluminum oxide powder, from about 25 percent by weight to about 37 percent by weight aluminum metal powder or aluminum oxide powder, from about 27 percent by weight to about 35 percent by weight aluminum metal powder or aluminum oxide powder, from about 29 percent by weight to about 33 percent by weight aluminum metal powder or aluminum oxide powder, or even about 31 percent by weight aluminum metal powder or aluminum oxide powder.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the zinc portion of component (A2a) is formed from about 56 percent by weight to about 72 percent by weight zinc metal powder or zinc oxide powder, from about 58 percent by weight to about 70 percent by weight zinc metal powder or zinc oxide powder, from about 60 percent by weight to about 68 percent by weight zinc metal powder or zinc oxide powder, from about 62 percent by weight to about 66 percent by weight zinc metal powder or zinc oxide powder, or even about 64 percent by weight zinc metal powder or zinc oxide powder.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the magnesium portion of component (A2a) is formed from about 1.5 percent by weight to about 8.5 percent by weight magnesium metal powder or magnesium oxide powder, from about 2 percent by weight to about 8 percent by weight magnesium metal powder or magnesium oxide powder, from about 2.5 percent by weight to about 7.5 percent by weight magnesium metal powder or magnesium oxide powder, from about 3 percent by weight to about 7 percent by weight magnesium metal powder or magnesium oxide powder, from about 3.5 percent by weight to about 6.5 percent by weight magnesium metal powder or magnesium oxide powder, from about 4 percent by weight to about 6 percent by weight magnesium metal powder or magnesium oxide powder, or even about 5 percent by weight magnesium metal powder or magnesium oxide powder.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • component (A2b) of Part (A2) - the phosphoric acid (H3P04) - can be replaced by a mixture of one or more other phosphoric acids or phosphoric anhydrides including, but not limited to, one or more of orthophosphoric acid (H3P04) (also referred to herein as just phosphoric acid), pyrophosphoric acid (H4P207), tripolyphosphoric acid p5 P 30io ), tetrapolyphosphoric acid (H 6P4013) , trimetaphosphoric acid (H 3P309) , phosphoric anhydride (P 40io) and/or pyrophosphoric acid (H 4 P 207 ).
  • orthophosphoric acid H3P04
  • H4P207 also referred to herein as just phosphoric acid
  • tripolyphosphoric acid p5 P 30io tripolyphosphoric acid p5 P 30io
  • tetrapolyphosphoric acid H 6P4013
  • trimetaphosphoric acid H
  • component (A2b) of Part (A2) - the phosphoric acid (H3P04) - can be replaced by a mixture of two or more of the above phosphoric acids or phosphoric anhydrides, three or more of the above phosphoric acids or phosphoric anhydrides, four or more of the above phosphoric acids or phosphoric anhydrides, or even five or more of the above phosphoric acids or phosphoric anhydrides.
  • component (A2b) is phosphoric acid (H3P04)
  • concentration of the acid used for component (A2b) is 85 percent by weight.
  • various other concentrations of acids can be used for component (A2b) but the amount of component (A2b) in Part (A2), as detailed herein, is based on the use of phosphoric acid (H3P04) with a concentration of 85 percent by weight. Accordingly, should a different compound be used for component (A2b), the amount thereof should be adjusted to yield the same amount of acid as if phosphoric acid (H3P04) with a concentration of 85 percent by weight were used to provide the desired weight percentage of component (A2b) as detailed below.
  • Part (A2) is an inorganic composition formed from components (A2a), (A2b) and (A2c), where Part (A2) has less than about 7.5 percent by weight carbon and/or other organic compounds, has less than about 5 percent by weight carbon and/or other organic compounds, has less than about 2.5 percent by weight carbon and/or other organic compounds, has less than about 1 percent by weight carbon and/or other organic compounds, has less than about 0.5 percent by weight carbon and/or other organic compounds, has less than about 0.1 percent by weight carbon and/or other organic compounds, or is even free of (that is has zero percent by weight) carbon and/or other organic compounds.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (A2) can further optionally include one or more additional additives such as colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray-dried granules), or mixtures of any two or more, three or more, four or more, or even five or more thereof.
  • additional additives such as colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or
  • additives may be organic in nature. Such additives are utilized to impart various desired properties to the mixture that forms the basis of Part (A2) of the present invention and permits Part (A2) to have improved shelf-life, improved rheological properties, improved mixability and/or spray ability, etc.
  • Part (A2) will include a minor amount of organic material.
  • minor amount it is meant that Part (A2) will have less than about 7.5 percent by weight carbon and/or other organic compounds, will have less than about 7 percent by weight carbon and/or other organic compounds, will have less than about 6.5 percent by weight carbon and/or other organic compounds, will have less than about 6 percent by weight carbon and/or other organic compounds, will have less than about 5.5 percent by weight carbon and/or other organic compounds, will have less than about 5 percent by weight carbon and/or other organic compounds, will have less than about 4.5 percent by weight carbon and/or other organic compounds, will have less than about 4 percent by weight carbon and/or other organic compounds, will have less than about 3.5 percent by weight carbon and/or other organic compounds, will have less than about 3.
  • percent by weight carbon and/or other organic compounds will have less than about 2.5 percent by weight carbon and/or other organic compounds, will have less than about 1 percent by weight carbon and/or other organic compounds, or will even have less than about 0.5 percent by weight carbon and/or other organic compounds.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (A2) is formed from about 5 percent by weight to about 17 percent by weight component (A2a), from about 44 percent by weight to about 64 percent by weight component (A2b) and from about 24 percent by weight to about 44 percent by weight component (A2c).
  • Part (A2) can further include one or more additional additives such as one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan granulation, seed coatings, extruded and/or spray-dried granules), or mixtures of any two or more, three or more, four or more, or even five or more thereof are present in total, or even individually, at a range of about 0.1 percent by weight to about 3 percent by weight.
  • additional additives such as one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers,
  • Part (A2) further includes one or more additional additives such as one or more clay-based rheology modifiers (e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF) at a range of about 0.1 percent by weight to about 2.5 percent by weight and/or one or more lignin compounds such as a calcium lignosulphonate at a range of about 0.1 percent by weight to about 2.5 percent by weight.
  • the total amount of each component and/or optional component of Part (A2) may individually total more than 100 weight percent when each component is taken individually and totaled using the broadest amounts disclosed herein, one of skill in the art will realize that this is not the case.
  • Part (A2) can be varied within any stated range as desired in order to achieve a total weight percent of 100.
  • Part (A2) is formed from about 7 percent by weight to about 15 percent by weight component (A2a), from about 8 percent by weight to about 14 percent by weight component (A2a), from about 9 percent by weight to about 13 percent by weight component (A2a), from about 10 percent by weight to about 12 percent by weight component (A2a), or even about 11 percent by weight component (A2a).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the weight amount of component (A2a) is formed from the various weight ranges of the one or more metal powders and/or metal oxide powders discussed above in connection with component (A2a).
  • the weight ranges for the one or more metal powders and/or metal oxide powders of component (A2a) are based on the portions of such one or more metal powders and/or metal oxide powders in the weight amount of component (A2a). That is, the weight amount of component (A2a) is treated as a full 100 weight percent amount to calculate the weight portion amounts of the one or more metal powders and/or metal oxide powders of component (A2a).
  • Part (A2) is formed from about 46 percent by weight to about 62 percent by weight component (A2b), from about 48 percent by weight to about 60 percent by weight component (A2b), from about 50 percent by weight to about 58 percent by weight component (A2b), from about 52 percent by weight to about 56 percent by weight component (A2b), or even about 54 percent by weight component (A2b).
  • A2b percent by weight component
  • A2b percent by weight component
  • A2b is formed from about 46 percent by weight to about 62 percent by weight component (A2b), from about 48 percent by weight to about 60 percent by weight component (A2b), from about 50 percent by weight to about 58 percent by weight component (A2b), from about 52 percent by weight to about 56 percent by weight component (A2b), or even about 54 percent by weight component (A2b).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (A2) is formed from about 26 percent by weight to about 42 percent by weight component (A2c), from about 28 percent by weight to about 40 percent by weight component (A2c), from about 30 percent by weight to about 38 percent by weight component (A2c), or even about 34 percent by weight component (A2c).
  • A2c percent by weight to about 42 percent by weight component
  • A2c percent by weight component
  • A2c percent by weight component
  • A2c percent by weight component
  • A2c is formed from about 30 percent by weight to about 38 percent by weight component (A2c), or even about 34 percent by weight component (A2c).
  • the one or more additional additives such as the one or more clay-based rheology modifiers (e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF) are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • the one or more clay-based rheology modifiers e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF
  • the one or more additional additives such as the one or more lignin compounds such as a calcium lignosulphonate are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (A2) is formed by the following procedure: Step (i) prepare 52 percent by weight H 3 P 04 solution via the following procedure - take 50 grams of 85 percent by weight H 3 P 04 solution and add 32 grams of water, then mix well to yield 82 grams of the desired concentration of H 3 P 04 solution; Step (ii) stir in 3.45 grams of aluminum metal powder into the H 3 P 04 solution - additionally, the solution should be heated if needed to dissolve A1 so as to obtain a clear fluid when all aluminum metal powder is dissolved; Step (iii) add 7.2 grams of zinc metal powder into this solution, keep stirring until all of the zinc metal powder is dissolved - the resulting solution should still look very clear; and Step (iv) one can stop at this point to yield a Part (A2) solution that is suitable for use with either Part (Bl) or Part (B2) as a coating for glass applications.
  • Step (v) add 0.56 grams of magnesium metal powder to the solution from Step (iii) above and stir until all of the magnesium metal powder is dissolved; Step (vi) keep the solution stirring for about one hour, measure the pH thereof, it should be around 3; Step (vii) measure the pH next day, it may increase slightly over night, but should be between about 3 and about 3.3.
  • This solution is good for use in metal coating applications (such as a coating for carbon steel) when combined, as will be detailed below, with one of Part (Bl) or Part (B2) coatings on carbon steel.
  • Part (A2) can be placed in a suitable shipping container for use at a later date as will be described below, with one or more of Part (Bl) and/or Part (B2).
  • any one or more optional additives described herein can be added to Part (A2).
  • Part (Bl) is in one embodiment formed from a combination of: (Bla) at least one silica-based glass powder or equivalent thereof; (Bib) at least one metal oxide or an equivalent thereof; and (Blc) water.
  • component (Bla) is formed from a mixture of four inorganic compounds: silicon dioxide (i.e., silica - Si02) or an equivalent, at least one form of aluminum oxide (i.e., alumina - A1203) whether anhydrous or hydrated, calcium fluoride (CaF2) and sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6) that are mixed together (in one instance all four of the above-listed compounds are in powder form), vitrified and then powderized/pulverized/crushed into a powder to form component (Bla) of Part (Bl).
  • silicon dioxide i.e., silica - Si02
  • at least one form of aluminum oxide i.e., alumina - A1203 whether anhydrous or hydrated
  • calcium fluoride (CaF2) and sodium hexafluoroaluminate i.e., cryolite - Na3AlF6
  • aluminosilicate based material for component (Bla) is formed from a combination of about 23 percent by weight to about 43 percent by weight of silicon dioxide (i.e., silica - Si02), from about 23 percent by weight to about 43 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), whether anhydrous or hydrated, from about 18 percent by weight to about 38 percent by weight of calcium fluoride (CaF2), and from about 1 percent by weight to about 11 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6).
  • silicon dioxide i.e., silica - Si02
  • aluminum oxide i.e., alumina - A1203
  • CaF2 calcium fluoride
  • cryolite - Na3AlF6 sodium hexafluoroaluminate
  • each component and/or optional component of component (Bla) may individually total more than 100 weight percent when each component is taken individually and totaled using the broadest amounts disclosed herein, one of skill in the art will realize that this is not the case. Rather, each individual component of component (Bla) can be varied within any stated range as desired in order to achieve a total weight percent of 100.
  • component (Bla) is formed from about 25 percent by weight to about 41 percent by weight of silicon dioxide (i.e., silica - Si02), from about 27 percent by weight to about 39 percent by weight of silicon dioxide (i.e., silica - Si02), from about 29 percent by weight to about 37 percent by weight of silicon dioxide (i.e., silica - Si02), from about 31 percent by weight to about 35 percent by weight of silicon dioxide (i.e., silica - Si02), or even about 33 percent by weight of silicon dioxide (i.e., silica - Si02).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • component (Bla) is formed from about 25 percent by weight to about 41 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), from about 27 percent by weight to about 39 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), from about 29 percent by weight to about 37 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), from about 31 percent by weight to about 35 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), or even about 33 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203).
  • component (Bla) is formed from about 20 percent by weight to about 36 percent by weight of calcium fluoride (CaF2), from about 22 percent by weight to about 34 percent by weight of calcium fluoride (CaF2), from about 24 percent by weight to about 32 percent by weight of calcium fluoride (CaF2), from about 26 percent by weight to about 30 percent by weight of calcium fluoride (CaF2), or even about 28 percent by weight of calcium fluoride (CaF2).
  • component (Bla) is formed from about 20 percent by weight to about 36 percent by weight of calcium fluoride (CaF2), from about 22 percent by weight to about 34 percent by weight of calcium fluoride (CaF2), from about 24 percent by weight to about 32 percent by weight of calcium fluoride (CaF2), from about 26 percent by weight to about 30 percent by weight of calcium fluoride (CaF2), or even about 28 percent by weight of calcium fluoride (CaF2).
  • individual range values can be combined to form additional and/or non-disclosed range
  • component (Bla) is formed from about 2 percent by weight to about 10 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), from about 3 percent by weight to about 9 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), from about 4 percent by weight to about 8 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), from about 5 percent by weight to about 7 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), or even about 6 percent by weight sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6).
  • sodium hexafluoroaluminate i.e., cryolite - Na3AlF6
  • vitrification is conducted on the aforementioned mixture of four powdered components at a temperature of at least about 1300 °C for a period of at least about three hours.
  • Higher vitrification temperatures can be used if required for complete vitrification of the powder.
  • the vitrification temperature can be at least about
  • vitrification is conducted at any suitable temperature as detailed above for at least about 3.5 hours, at least about 4 hours, at least about 4.5 hours, at least about 5 hours, at least about 5.5 hours, or even at least about 6 hours.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the resulting melt is subjected to normal cooling procedures by setting aside the vitrified mixture and allowing same to gradually and naturally cool to room temperature. This is accomplished by taking the glass melt out of a kiln and pouring same onto a bed of silica material. No special steps need be taken to avoid any fracture resulting from shock cooling, as the vitrified glass material is subsequently be ground to very fine powder per the procedure below.
  • Pulverization of the vitrified product to yield component (Bla) for use in Part (Bl) is accomplished using a mortar and pestle, or some other suitable equipment, until the particle of the ground up vitrified material is as follows: average particle size is about 10 pm, at least about 75 percent by weight of the particles have a particle size of less than about 5 pm, all of the ground up vitrified particles have a particle size of less than about 15 pm, and the surface area of any given particle is on average about 0.87 pnr 1 .
  • component (Bib) is formed from one or more metal oxide powders selected from one or more aluminum oxide powders, one or more zinc oxide powders, one or more iron oxide powders, one or more titanium oxide powders, one or more magnesium oxide powders, one or more copper oxide powders, one or more manganese oxide powders, one or more or calcium oxide powders, any mixture of two or more thereof, or any mixture of three or more thereof, or any mixture of four or more thereof, or even any mixture of five or more thereof.
  • component (Bib) is formed from a mixture of one or more magnesium oxide powders.
  • any of the additional metal oxide compounds listed above can optionally be added as additional compounds at similar amounts as specified below for the rheology modifiers and/or the one or more lignin compounds.
  • Part (Bl) is an inorganic composition formed from components (Bla), (Bib) and (Blc), where Part (Bl) has less than about 7.5 percent by weight carbon and/or other organic compounds, has less than about 5 percent by weight carbon and/or other organic compounds, has less than about 2.5 percent by weight carbon and/or other organic compounds, has less than about 1 percent by weight carbon and/or other organic compounds, has less than about 0.5 percent by weight carbon and/or other organic compounds, has less than about 0.1 percent by weight carbon and/or other organic compounds, or is even free of (that is has zero percent by weight) carbon and/or other organic compounds.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (Bl) can further optionally include one or more additional additives such as one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray-dried granules), one or more fibers, one or more milled glass fibers (e.g., fiberglass fibers, etc.), one or more kaolin bearing compounds, one or more types and/or concentrations of boric acid (e.g., H3B03), or mixtures of any two or more, three or more, four or more, or even five or
  • additional additives such as one
  • additives may be organic in nature. Such additives are utilized to impart various desired properties to the mixture that forms the basis of Part (Bl) of the present invention and permits Part (Bl) to have improved shelf-life, improved rheological properties, improved mixability and/or sprayability, improved coating strength, etc.
  • the terms "-bearing compound(s)” and “-containing compound(s)” are used interchangeably.
  • the terms “kaolin-bearing compound” and “kaolin- containing compound” are to be construed as the same and as noted above are utilized interchangeably.
  • this distinction applies equally to all terms that utilize the same constructs noted herein.
  • the kaolin-bearing compound(s) of the present invention is/are any kaolin-containing compound (e.g., kaolinite which is a mineral that is contained in kaolin clays and which has a chemical composition of A12Si205(0H)4).
  • kaolin is defined to mean, and encompass, any clay that contains a sufficient amount of kaolin therein (e.g., any clay that is at least 50 weight percent kaolin), or any clay or other compound that contains a sufficient amount of the mineral kaolinite (A12Si205(0H)4) (e.g., any clay, or other compound, that is at least 50 weight percent kaolinite).
  • Part (Bl) will include a minor amount of organic material.
  • minor amount it is meant that Part (Bl) will have less than about 7.5 percent by weight carbon and/or other organic compounds, will have less than about 7 percent by weight carbon and/or other organic compounds, will have less than about 6.5 percent by weight carbon and/or other organic compounds, will have less than about 6 percent by weight carbon and/or other organic compounds, will have less than about 5.5 percent by weight carbon and/or other organic compounds, will have less than about 5 percent by weight carbon and/or other organic compounds, will have less than about 4.5 percent by weight carbon and/or other organic compounds, will have less than about 4 percent by weight carbon and/or other organic compounds, will have less than about 3.5 percent by weight carbon and/or other organic compounds, will have less than about 3.
  • Part (Bl) is formed from about 30 percent by weight to about 50 percent by weight component (Bla), from about 12 percent by weight to about 32 percent by weight component (Bib) and from about 23 percent by weight to about 43 percent by weight component (Blc).
  • Part (Bl) can further include one or more colorants, one or more anti-setling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray-dried granules), one or more fibers, one or more milled glass fibers (e.g., fiberglass fibers, etc.), one or more kaolin-bearing compounds, one or more types and/or concentrations of boric acid (e.g., H3B03), or mixtures of any two or more, three or more, four or more, or even five or more thereof are present in total, or even individually, at
  • Part (Bl) further includes one or more additional additives such as one or more additional additives such as one or more clay-based rheology modifiers (e.g., one or more clay -based rheology modifiers such as Attagel ® a phyllosilicate clay rheology modifier from BASF) at a range of about 0.1 percent by weight to about 2.5 percent by weight, the one or more lignin compounds such as a calcium lignosulphonate at a range of about 0.1 percent by weight to about 2.5 percent, the one or more milled glass fibers such as fiberglass fibers at a range of about 0.1 percent by weight to about 5 percent and/or the one or more kaolin compounds or kaolin-bearing compounds at a range of about 0.1 percent by weight to about 5 percent by weight.
  • one or more clay-based rheology modifiers e.g., one or more clay -based rheology modifiers such as Attagel ® a phyllosilicate clay rheology
  • each component and/or optional component of Part (Bl) may individually total more than 100 weight percent when each component is taken individually and totaled using the broadest amounts disclosed herein, one of skill in the art will realize that this is not the case. Rather, each individual component of Part (Bl) can be varied within any stated range as desired in order to achieve a total weight percent of 100.
  • Part (Bl) is formed from about 32 percent by weight to about 48 percent by weight component (Bla), from about 34 percent by weight to about 46 percent by weight component (Bla), from about 36 percent by weight to about 44 percent by weight component (Bla), from about 38 percent by weight to about 42 percent by weight component (Bla), or even about 40 percent by weight component (Bla).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (Bl) is formed from about 14 percent by weight to about 30 percent by weight component (Bib), from about 16 percent by weight to about 28 percent by weight component (Bib), from about 18 percent by weight to about 26 percent by weight component (Bib), from about 20 percent by weight to about 24 percent by weight component (Bib), or even about 22 percent by weight component (Bib).
  • Part (Bl) is formed from about 25 percent by weight to about 41 percent by weight component (Blc), from about 27 percent by weight to about 39 percent by weight component (Blc), from about 29 percent by weight to about 37 percent by weight component (Blc), from about 31 percent by weight to about 35 percent by weight component (Blc), or even about 33 percent by weight component (Blc).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the one or more colorants, one or more anti-setling compounds e.g., thixotropic agents, one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium bgnosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray-dried granules), one or more fibers, one or more milled glass fibers (e.g., fiberglass fibers, etc.), one or more kaolin-bearing compounds, one or more types and/or concentrations of boric acid (e.g., H3B03), or mixtures of any two or more, three or more, four or more, or even five or more thereof are present in total, or even individually,
  • the one or more additional additives such as the one or more clay-based rheology modifiers (e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosibcate clay rheology modifier from BASF) are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • the one or more clay-based rheology modifiers e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosibcate clay rheology modifier from BASF
  • the one or more additional additives such as the one or more lignin compounds such as a calcium lignosulphonate are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the one or more additional additives such as the one or more milled glass fibers such as fiberglass fibers are present at a range of about 0.3 percent by weight to about 4.8 percent by weight, about 0.5 percent by weight to about 4.6 percent by weight, about 0.7 percent by weight to about 4.4 percent by weight, about 0.9 percent by weight to about 4.2 percent by weight, about 1.1 percent by weight to about 4 percent by weight, about 1.3 percent by weight to about 3.8 percent by weight, about 1.5 percent by weight to about 3.6 percent by weight, about 1.7 percent by weight to about 3.4 percent by weight, about 1.9 percent by weight to about 3.2 percent by weight, about 2.1 percent by weight to about 3 percent by weight, about 2.3 percent by weight to about 2.8 percent by weight, or even at about 2.5 percent by weight.
  • the one or more additional additives such as the one or more kaolin compounds or kaolin-bearing compounds are present at a range of about 0.3 percent by weight to about 4.8 percent by weight, about 0.5 percent by weight to about 4.6 percent by weight, about 0.7 percent by weight to about 4.4 percent by weight, about 0.9 percent by weight to about 4.2 percent by weight, about 1.1 percent by weight to about 4 percent by weight, about 1.3 percent by weight to about 3.8 percent by weight, about 1.5 percent by weight to about 3.6 percent by weight, about 1.7 percent by weight to about 3.4 percent by weight, about 1.9 percent by weight to about 3.2 percent by weight, about 2.1 percentby weight to about 3 percent by weight, about 2.3 percent by weight to about 2.8 percent by weight, or even at about 2.5 percent by weight.
  • Part (Bl) is formed by the following procedure: Step (i) measure 26 pounds (or roughly 3.12 gallons) of water in a suitable container or bucket (component (Blc) - tap water or any other suitable type of water such as distilled water will suffice), Step (ii) pour the desired amount of water into a suitably sized mixer and start the mixer; Step (iii) as the mixer is mixing, slowly add 40 pounds of component (Bla) and continue to mix; Step (iv) as the water / component (Bla) mixture is mixing slowly add 17.1 pounds of component (Bib) (in this case it is magnesium oxide powder but can be other meal oxide powders as noted above), continue to mix the resulting mixture slowly; and Step (v) add 1 pound of each of the optional additives (i.e., the milled fibers, the kaolin, the Attagel ® and
  • Part (B2) is in one embodiment formed from a combination of: (B2a) at least one silica-based glass powder or equivalent thereof; (B2b) at least one metal oxide or an equivalent thereof; and (B2c) water.
  • component (B2a) is formed from a mixture of four inorganic compounds: silicon dioxide (i.e., silica - Si02) or an equivalent, at least one form of aluminum oxide (i.e., alumina - A1203) whether anhydrous or hydrated, calcium fluoride (CaF2) and sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6) that are mixed together (in one instance all four of the above-listed compounds are in powder form), vitrified and then powderized/pulverized/crushed into a powder to form component (B2a) of Part (B2).
  • silicon dioxide i.e., silica - Si02
  • at least one form of aluminum oxide i.e., alumina - A1203 whether anhydrous or hydrated
  • calcium fluoride (CaF2) and sodium hexafluoroaluminate i.e., cryolite - Na3AlF6
  • aluminosilicate based material for component (B2a) is formed from a combination of about 23 percent by weight to about 43 percent by weight of silicon dioxide (i.e., silica - Si02), from about 23 percent by weight to about 43 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), whether anhydrous or hydrated, from about 18 percent by weight to about 38 percent by weight of calcium fluoride (CaF2), and from about 1 percent by weight to about 11 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6).
  • silicon dioxide i.e., silica - Si02
  • aluminum oxide i.e., alumina - A1203
  • CaF2 calcium fluoride
  • cryolite - Na3AlF6 sodium hexafluoroaluminate
  • each component and/or optional component of component (B2a) may individually total more than 100 weight percent when each component is taken individually and totaled using the broadest amounts disclosed herein, one of skill in the art will realize that this is not the case. Rather, each individual component of component (B2a) can be varied within any stated range as desired in order to achieve a total weight percent of 100.
  • component (B2a) is formed from about 25 percent by weight to about 41 percent by weight of silicon dioxide (i.e., silica - Si02), from about 27 percent by weight to about 39 percent by weight of silicon dioxide (i.e., silica - Si02), from about 29 percent by weight to about 37 percent by weight of silicon dioxide (i.e., silica - Si02), from about 31 percent by weight to about 35 percent by weight of silicon dioxide (i.e., silica - Si02), or even about 33 percent by weight of silicon dioxide (i.e., silica - Si02).
  • silicon dioxide i.e., silica - Si02
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • component (B2a) is formed from about 25 percent by weight to about 41 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), from about 27 percent by weight to about 39 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), from about 29 percent by weight to about 37 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), from about 31 percent by weight to about 35 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203), or even about 33 percent by weight of at least one form of aluminum oxide (i.e., alumina - A1203).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • component (B2a) is formed from about 20 percent by weight to about 36 percent by weight of calcium fluoride (CaF2), from about 22 percent by weight to about 34 percent by weight of calcium fluoride (CaF2), from about 24 percent by weight to about 32 percent by weight of calcium fluoride (CaF2), from about 26 percent by weight to about 30 percent by weight of calcium fluoride (CaF2), or even about 28 percent by weight of calcium fluoride (CaF2).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • component (B2a) is formed from about 2 percent by weight to about 10 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), from about 3 percent by weight to about 9 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), from about 4 percent by weight to about 8 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), from about 5 percent by weight to about 7 percent by weight of sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6), or even about 6 percent by weight sodium hexafluoroaluminate (i.e., cryolite - Na3AlF6).
  • individual range values can be combined to form additional and/or non-disclosed range
  • component (B2a) contains silicon dioxide (i.e., silica) and aluminum oxide (i.e., alumina), a crucible formed from either of these materials are compatible for mixing the materials prior to the vitrification thereof.
  • a suitable crucible formed from a suitable material assures that there will be no serious contamination issue with the powders used to form component (B2a) prior to vitrification.
  • vitrification is conducted on the aforementioned mixture of four powdered components at a temperature of at least about 1300 °C for a period of at least about three hours.
  • Higher vitrification temperatures can be used if required for complete vitrification of the powder.
  • the vitrification temperature can be at least about
  • vitrification is conducted at any suitable temperature as detailed above for at least about 3.5 hours, at least about 4 hours, at least about 4.5 hours, at least about 5 hours, at least about 5.5 hours, or even at least about 6 hours.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the resulting melt is subjected to normal cooling procedures by setting aside the vitrified mixture and allowing same to gradually and naturally cool to room temperature. This is accomplished by taking the glass melt out of a kiln and pouring same onto a bed of silica material. No special steps need be taken to avoid any fracture resulting from shock cooling, as the vitrified glass material is subsequently be ground to very fine powder per the procedure below.
  • Pulverization of the vitrified product to yield component (B2a) for use in Part (B2) is accomplished using a mortar and pestle, or some other suitable equipment, until the particle of the ground up vitrified material is as follows: average particle size is about 10 pm, at least about 75 percent by weight of the particles have a particle size of less than about 5 pm, all of the ground up vitrified particles have a particle size of less than about 15 pm, and the surface area of any given particle is on average about 0.87 pnr 1 .
  • component (B2b) is formed from one ormore metal oxide powders selected from one or more aluminum oxide powders, one or more zinc oxide powders, one or more iron oxide powders, one or more titanium oxide powders, one or more magnesium oxide powders, one or more copper oxide powders, one or more manganese oxide powders, one or more or calcium oxide powders, or any mixture of two or more thereof, or any mixture of three or more thereof, or any mixture of four or more thereof, or even any mixture of five or more thereof.
  • component (B2b) is formed from a mixture of one or more zinc oxide powders.
  • any of the additional metal oxide compounds listed above can optionally be added as additional compounds at similar amounts as specified below for the rheology modifiers and/or the one or more lignin compounds.
  • Part (B2) is an inorganic composition formed from components (B2a), (B2b) and (B2c), where Part (B2) has less than about 7.5 percent by weight carbon and/or other organic compounds, has less than about 5 percent by weight carbon and/or other organic compounds, has less than about 2.5 percent by weight carbon and/or other organic compounds, has less than about 1 percent by weight carbon and/or other organic compounds, has less than about 0.5 percent by weight carbon and/or other organic compounds, has less than about 0.1 percent by weight carbon and/or other organic compounds, or is even free of (that is has zero percent by weight) carbon and/or other organic compounds.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (B2) can further optionally include one or more colorants, one or more anti-settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan granulation, seed coatings, extruded and/or spray-dried granules), one or more fibers, one or more milled glass fibers (e.g., fiberglass fibers, etc.), one or more kaolin-bearing compounds, one or more types and/or concentrations of boric acid (e.g., H3B03), or mixtures of any two or more, three or more, four or more, or even five or more thereof.
  • anti-settling compounds e.g.
  • additives may be organic in nature. Such additives are utilized to impart various desired properties to the mixture that forms the basis of Part (B2) of the present invention and permits Part (B2) to have improved shelf-life, improved rheological properties, improved mixability and/or spray ability, improved coating strength, etc.
  • the terms "-bearing compound(s)” and “-containing compound(s)” are used interchangeably.
  • the terms “kaolin-bearing compound” and “kaolin- containing compound” are to be construed as the same and as noted above are utilized interchangeably.
  • this distinction applies equally to all terms that utilize the same constructs noted herein.
  • the kaolin-bearing compound(s) of the present invention is/are any kaolin-containing compound (e.g., kaolinite which is a mineral that is contained in kaolin clays and which has a chemical composition of A12Si205(0H)4).
  • kaolin is defined to mean, and encompass, any clay that contains a sufficient amount of kaolin therein (e.g, any clay that is at least 50 weight percent kaolin), or any clay or other compound that contains a sufficient amount of the mineral kaolinite (A12Si205(0H)4) (e.g, any clay, or other compound, that is at least 50 weight percent kaolinite).
  • Part (B2) will include a minor amount of organic material.
  • minor amount it is meant that Part (B2) will have less than about 7.5 percent by weight carbon and/or other organic compounds, will have less than about 7 percent by weight carbon and/or other organic compounds, will have less than about 6.5 percent by weight carbon and/or other organic compounds, will have less than about 6 percent by weight carbon and/or other organic compounds, will have less than about 5.5 percent by weight carbon and/or other organic compounds, will have less than about 5 percent by weight carbon and/or other organic compounds, will have less than about 4.5 percent by weight carbon and/or other organic compounds, will have less than about 4 percent by weight carbon and/or other organic compounds, will have less than about 3.5 percent by weight carbon and/or other organic compounds, will have less than about 3.
  • percent by weight carbon and/or other organic compounds will have less than about 2.5 percent by weight carbon and/or other organic compounds, will have less than about 1 percent by weight carbon and/or other organic compounds, or will even have less than about 0.5 percent by weight carbon and/or other organic compounds.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (B2) is formed from about 12 percent by weight to about 32 percent by weight component (B2a), from about 30 percent by weight to about 50 percent by weight component (B2b) and from about 25 percent by weight to about 45 percent by weight component (B2c).
  • Part (B2) can further include one or more colorants, one or more anti-setling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray-dried granules), one or more fibers, one or more milled glass fibers (e.g., fiberglass fibers, etc.), one or more kaolin-bearing compounds, one or more types and/or concentrations of boric acid (e.g., H3B03), or mixtures of any two or more, three or more, four or more, or even five or more thereof are present in total, or even individually, at
  • Part (B2) further includes one or more additional additives such as one or more additional additives such as one or more clay-based rheology modifiers (e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosibcate clay rheology modifier from BASF) at a range of about 0.1 percent by weight to about 2.5 percent by weight, the one or more lignin compounds such as a calcium lignosulphonate at a range of about 0.1 percent by weight to about 2.5 percent, the one or more milled glass fibers such as fiberglass fibers at a range of about 0.1 percent by weight to about 5 percent and/or the one or more kaolin compounds or kaolin-bearing compounds at a range of about 0.1 percent by weight to about 5 percent by weight.
  • one or more clay-based rheology modifiers e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosibcate clay rheology modifier
  • Part (B2) is formed from about 14 percent by weight to about 30 percent by weight component (B2a), from about 16 percent by weight to about 28 percent by weight component (B2a), from about 18 percent by weight to about 26 percent by weight component (B2a), from about 20 percent by weight to about 24 percent by weight component (B2a), or even about 22 percent by weight component (B2a).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (B2) is formed from about 32 percent by weight to about 48 percent by weight component (B2b), from about 34 percent by weight to about 46 percent by weight component (B2b), from about 36 percent by weight to about 44 percent by weight component (B2b), from about 38 percent by weight to about 42 percent by weight component (B2b), or even about 40 percent by weight component (B2b).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • Part (B2) is formed from about 27 percent by weight to about 43 percent by weight component (B2c), from about 29 percent by weight to about 41 percent by weight component (B2c), from about 31 percent by weight to about 39 percent by weight component (B2c), from about 33 percent by weight to about 37 percent by weight component (B2c), or even about 35 percent by weight component (B2c).
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the one or more colorants, one or more anti-setling compounds e.g., thixotropic agents, one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium bgnosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray-dried granules), one or more fibers, one or more milled glass fibers (e.g., fiberglass fibers, etc.), one or more kaolin-bearing compounds, one or more types and/or concentrations of boric acid (e.g., H3B03), or mixtures of any two or more, three or more, four or more, or even five or more thereof are present in total, or even individually,
  • the one or more additional additives such as the one or more clay-based rheology modifiers (e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosibcate clay rheology modifier from BASF) are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • the one or more clay-based rheology modifiers e.g., one or more clay-based rheology modifiers such as Attagel ® a phyllosibcate clay rheology modifier from BASF
  • the one or more additional additives such as the one or more lignin compounds such as a calcium lignosulphonate are present at a range of about 0.3 percent by weight to about 2.3 percent by weight, about 0.5 percent by weight to about 2.1 percent by weight, about 0.7 percent by weight to about 1.9 percent by weight, about 0.9 percent by weight to about 1.7 percent by weight, about 1.1 percent by weight to about 1.5 percent by weight, or even at about 1.3 percent by weight.
  • individual range values can be combined to form additional and/or non-disclosed ranges.
  • the one or more additional additives such as the one or more milled glass fibers such as fiberglass fibers are present at a range of about 0.3 percent by weight to about 4.8 percent by weight, about 0.5 percent by weight to about 4.6 percent by weight, about 0.7 percent by weight to about 4.4 percent by weight, about 0.9 percent by weight to about 4.2 percent by weight, about 1.1 percent by weight to about 4 percent by weight, about 1.3 percent by weight to about 3.8 percent by weight, about 1.5 percent by weight to about 3.6 percent by weight, about 1.7 percent by weight to about 3.4 percent by weight, about 1.9 percent by weight to about 3.2 percent by weight, about 2.1 percent by weight to about 3 percent by weight, about 2.3 percent by weight to about 2.8 percent by weight, or even at about 2.5 percent by weight.
  • the one or more additional additives such as the one or more kaolin compounds or kaolin-bearing compounds are present at a range of about 0.3 percent by weight to about 4.8 percent by weight, about 0.5 percent by weight to about 4.6 percent by weight, about 0.7 percent by weight to about 4.4 percent by weight, about 0.9 percent by weight to about 4.2 percent by weight, about 1.1 percent by weight to about 4 percent by weight, about 1.3 percent by weight to about 3.8 percent by weight, about 1.5 percent by weight to about 3.6 percent by weight, about 1.7 percent by weight to about 3.4 percent by weight, about 1.9 percent by weight to about 3.2 percent by weight, about 2.1 percent by weight to about 3 percent by weight, about 2.3 percent by weight to about 2.8 percent by weight, or even at about 2.5 percent by weight.
  • Part (B2) is formed by the following procedure: Step (i) measure 5.43 pounds of water in a suitable container or bucket (component (B2c) - tap water or any other suitable type of water such as distilled water will suffice), Step (ii) pour the desired amount of water into a suitably sized mixer and start the mixer; Step (iii) as the mixer is mixing, slowly add 3.41 pounds of component (B2a) and continue to mix; Step (iv) as the water / component (B2a) mixture is mixing slowly add 6.2 pounds of component (B2b) (in this case it is zinc oxide powder but can be other meal oxide powders as noted above), continue to mix the resulting mixture slowly; and Step (v) add 0.23 pounds of each of the optional additives (i.e., the milled fibers and the kaolin) one by one and mix until one obtains a
  • the coatings are of the present invention are produced by a chemical reaction (typically an acid-base reaction) between one or more of Part (Al) and/or Part (A2) with one or more of Part (Bl) and/or Part (B2).
  • the inventive coatings are formed from two pastes, one acidic (Part (Al) or Part (A2)) and the other being alkaline, or even neutral in pH (Part (Bl) or Part (B2)).
  • the acidic paste (Part (Al) or Part (A2)) acts as the activator via the phosphoric acid, polyphosphoric acid or acid phosphate contained therein and whose pH is adjusted to activate the alkaline, or neutral, paste (Part (Bl) or Part (B2)).
  • the alkaline paste (Part (Bl) or Part (B2)) can instead be formed to be neutral and contains the above noted silica glass component.
  • the silicon dioxide components of Part (Bla) and/or Part (B2a) can be replaced or supplemented with one or more calcium oxide powders (CaO), one or more aluminum powders (AI203) and/or boron oxide powder (B203) at the same weight percentages discussed above for components (Bla) and (B2a).
  • fumed silica and/or clean fly ash maybe used to augment the components (Bla) and (B2a) while still adhering to the weight percentages discussed above for components (Bla) and (B2a).
  • the coatings of the present invention can be applied using spray guns, brush or rollers to produce thin films on metals, on inorganic surfaces such as cement or concrete, or on a wood surface.
  • the coatings of the present invention form a chemical bond thereto due to one or more chemical reactions occurring between the application of a mixture of one or more of Part (Al) and/or Part (A2) with one or more of Part (Bl) and/or Part (B2).
  • the layer formed by this chemical bond is responsible for corrosion protection and can be referred to as a passivation layer.
  • This passivation layer can be further protected from external abrasion, impact and other stresses by a protective layer, which can be referred to as top layer.
  • a protective layer which can be referred to as top layer.
  • no heat-based curing step is required to achieve a coating in accordance with the present invention.
  • Both layers can be formed in a single spray of the coatings of the present invention and, thus, no second coat is needed unless one desires to build up a thickness beyond about 250 micrometers to about 500 micrometers (about 10 mils to about 20 mils) to exploit other properties such as superior insulation, longer chemical protection or esthetic surface formations. It should be noted that the present invention is not limited to solely coating thickness of only about 250 micrometers to about 500 micrometers.
  • the bond between the coatings of the present invention and wood tend to be only physical. While part of the applied mixed coating paste is absorbed into the pores of a wood surface, it then sets and holds the coating on the surface of wood by a physical bond and thus the absorbed coating layer acts like an anchor to the wood surface for the remainder of the coating layer. Thus, in one embodiment, no heat-based curing step is required to achieve a wood-coated article in accordance with the present invention.
  • the passivation layer on metals performs an important function of providing corrosion protection to a metal substrate. Especially in the case of steel, where corrosion is a major issue, the passivation layer reacts with iron (Fe) and forms an iron phosphate compound comprising strengite (i.e., FeP04*2H20) which is considered to be a very stable corrosion protective compound.
  • this passivation layer comprises a layer of tough phospho-silicate-aluminate glassy minerals which make the structure of the passivation layer tough, water impermeable and dense. Therefore, this passivation layer is very stable in a wide range of chemical environments including saline, acidic, alkaline and/or marine.
  • the presence and toughness of the passivation layer distinguishes the coatings of the present invention from other commercially available coatings.
  • most polymer emulsion-based coatings are simply a physical coating and do not have a passivation layer/effect.
  • Available powder coatings also do not contribute to corrosion protection other than as physical barriers to a corroding environment. When breached, all of these coatings become vulnerable to environmental degradation of the entire coating by atmospheric blistering.
  • the coatings produced via the present invention even when a topcoat thereof is breached, do not expose the underlying metal substrate to external exposure since the passivation layer itself is very tough and cannot easily be breached.
  • Passivation layers can be formed by applying a primer, such as phosphoric acid, or one or more oxide-based chemically-bonded phosphate ceramics available in the market.
  • a primer such as phosphoric acid, or one or more oxide-based chemically-bonded phosphate ceramics available in the market.
  • all of these materials require a second coat that is polymeric in nature and which needs to be applied after the first coat is cured. This necessitates a second round of application.
  • the coatings of the present invention permit one to obtain a desired coating in a single spray application which produces both a passivation layer as well as a protective coating/layer.
  • the coatings of the present invention are pore-free, dense, slightly flexible ceramic coatings with a glass-crystalline structure. They provide protection to a desired coated surface from external deterioration mechanisms of impact, abrasion, fire, and chemical and biological attacks.
  • the coatings of the present invention are applied by mixing one of Part (Al) or Part (A2) with one of Part (Bl) or Part (B2) so that the desired chemical reaction between the two parts is initiated.
  • this is done by using a plural pump system, in which two separate pumps force one of Part (Al) or Part (A2) together with one of Part (Bl) or Part (B2) into a static mixer, which mixes the two components and the desired chemical reaction is initiated in the parts.
  • the reacting material is then sprayed under pressure onto a desired substrate. This method mimics that of a two-part epoxy system and hence a similar plural pumping system can be utilized.
  • the coatings of the present invention are formed when the mixture of one or more of Part (Al) and/or Part (A2) together with one or more of Part (Bl) and/or Part (B2) is activated by the acidic medium of the one or more phosphate-containing compounds of either Part (Al) and/or (Part (A2).
  • Part (Al) and/or Part (A2) are mixed together with one of Part (Bl) and/or Part (B2), they react and form silicate, aluminate, and aluminosilicate mineral complexes that are partially in glassy phases.
  • the resulting structures are very similar to many of the natural phosphate minerals, such as apatite and man-made glass ceramics. The difference, however, is that nature produces these minerals at high temperature without using water, while the present invention discloses a similar material formed at room temperature in an aqueous medium by acid-base reaction of the disclosed materials.
  • the flexural strength of the coatings of the present invention can be enhanced by adding fine whiskers of glass or minerals, such as wollastonite (CaSi03) to Part (Bl) and/or Part (B2).
  • coarse whiskers of glass or minerals such as wollastonite (CaSi03)
  • cellulosic fibers also if these coatings are not designed for high temperature applications (typically these are also added to Part (Bl) and/or Part (B2)).
  • Some of these additives will react sparsely with the one or more phosphate- containing compounds of Part (Al) and/or Part (A2) and form their own bond, and some will be totally unreactive. Either way they enhance the flexural strength and elastic modulus of the coatings of the present invention.
  • the toughness of the coatings of the present invention can be enhanced by the optional addition of one or more hard particles and/or particles in platelet structures, such as fine-grained sand or kaolinite, which is in platelet form, in Part (Bl) and/or Part (B2).
  • Other optional additives are clay, calcined alumina (AI203), titanium dioxide (Ti02), zirconia (Zr02), etc. Inclusion of any particles that are unreactive in the acid-base reaction and exhibit extreme hardness will also serve this purpose.
  • the heat reflectivity of the coatings of the present invention can be enhanced for heat related applications by the optional addition of one or more heat reflecting minerals such as rutile or magnesia which can be added to Part (Bl) and/or Part (B2). These materials have a very high heat reflectivity (from about 90 percent to about 99.9 percent) and they enhance the heat reflectivity of the coatings of the present invention, which helps to keep the coated substrate cooler.
  • one or more heat reflecting minerals such as rutile or magnesia which can be added to Part (Bl) and/or Part (B2).
  • heat absorptive minerals in the form of powders to any of Part (Al), Part (A2), Part (Bl) and/or Part (B2) selected from black iron oxide (magnetite, Fe304), one or more iron oxides (e.g., wustite - FeO), lamp and/or carbon black and/or one or more manganese oxides (MnO and/or Mn304).
  • black iron oxide magnetite, Fe304
  • iron oxides e.g., wustite - FeO
  • lamp and/or carbon black and/or one or more manganese oxides MnO and/or Mn304.
  • the above materials can be added at a loading level of between about 0.1 percent by weight to about 25 percent by weight can be achieved without the loss of other favorable properties, and ideally at a level of about 10 percent by weight, to any of Part (Al), Part (A2), Part (Bl) and/or Part (B2) after these parts of the coatings of the present invention are formed per the disclosure detailed above.
  • optional additives are MgO, FeO, Fe304, and Mn304.
  • any of Parts (Al), (A2), (Bl) and/or (B2) can further optionally include one or more additional additives such as one or more colorants, one or more anti settling compounds (e.g., thixotropic agents), one or more viscosity modifiers, one or more thickeners (e.g., xanthan gum), one or more rheology modifiers, one or more pigments (e.g., Ti02), one or more lignin compounds such as a calcium lignosulphonate (e.g., Norlig A from Borregaard LignoTech a binder for pan-granulation, seed coatings, extruded and/or spray- dried granules), one or more fibers, one or more milled glass fibers (e.g., fiberglass fibers, etc.), one or more kaolin-bearing compounds, or mixtures of any two or more, three or more, four or more, or even five or more thereof at the various amounts
  • additional additives such as
  • one or more thickeners and/or one or more rheology modifiers any types of such compounds can be used in any one or more of Parts (Al), (A2), (Bl) and/or (B2) at the various amounts detailed above.
  • Some examples of various types of one or more viscosity modifiers, one or more thickeners and/or one or more rheology modifiers include, but are not limited to, alkali swellable emulsions (ASEs), hydrophobically-modified alkali swellable emulsions (HASEs), hydrophobically-modified ethoxylated urethane resins (HEURs), hydroxyethyl celluloses (HECs), nonionic synthetic associative thickeners (NSATs), one or more polysaccharides (e.g., xanthan gum), etc.
  • ASEs alkali swellable emulsions
  • HASEs hydrophobically-modified alkali swellable emulsions
  • HEURs hydrophobically-modified ethoxylated urethane resins
  • HECs hydroxyethyl celluloses
  • NSATs nonionic synthetic associative thickeners
  • viscosity modifiers there are many other types of viscosity modifiers, thickeners and/or rheology modifiers available such as multifunctional polymers, copolymers of acrylic acid, N-vinylpyrrolidone, cationic monomers (e.g., N-vinylimidazole) and hydrophobic monomers such as a long-chain ester of methacrylic acid having an ethoxylated spacer chain, preferably PEG-25 methacrylate that may be of use in connection with the compositions of the present invention.
  • multifunctional polymers copolymers of acrylic acid, N-vinylpyrrolidone, cationic monomers (e.g., N-vinylimidazole) and hydrophobic monomers such as a long-chain ester of methacrylic acid having an ethoxylated spacer chain, preferably PEG-25 methacrylate that may be of use in connection with the compositions of the present invention.
  • the one or more viscosity modifiers, one or more thickeners and/or one or more rheology modifiers of the present invention are not to be construed as limited to just any one specific type of compound, or even one specific chemical compound, rather any number of any one or more viscosity modifiers, any one or more thickeners and/or any one or more rheology modifiers disclosed herein can be utilized in the various embodiments of the present invention.
  • Another feature that makes the coatings of the present invention unique is that the coatings of the present invention are stable at high temperatures, even up to about 900 °C.
  • the coatings of the present invention are heat reflective, in combination with the thermal stability, and thus this makes the coatings of the present invention useful in unique applications such as for coating the interior of furnaces, high pressure steam pipes, hot fluid transport pipes, etc., where polymeric paints cannot be used.
  • the coatings of the present invention can optionally contain a very small amount of copper oxide, or even any other anti-bacterial compound, in either Part (Bl) and/or Part (OB2) so as to yield coatings with anti -fungal properties
  • the coatings of the present invention are typically white or beige once applied and set.
  • any suitable pigment and/or coloring agent, or even one or more suitable oxide- or silicate-based pigments can be added. Using these materials, a wide range of colors with different shades can be produced.
  • the coatings of the present invention have numerous applications and can also be produced in various solid forms. Such solid forms can be used as quick-setting binders, which are mixed with various aggregates and fillers and tailored to suitable applications such as rapid-setting grouts.
  • the material of the present invention when mixed from one of Part (Al) or Part (A2) together with one of Part (Bl) or Part (B2) can be, as noted above, used to produce a rapid-setting grout and/or concrete.
  • a binder such as sand, gravel, any suitable type of aggregate, waste materials such as fly ash, bottom ash, construction industry solid waste, solid mine tailings, byproduct waste streams such as leached out red mud from alumina industry in large proportions, etc. at a loading of about 15 percent by weight to about 60 percent by weight permits one to produce a rapid-setting grout that can be used as concrete, an injectable sealer for civil engineering applications and/or as a construction material.
  • the dense structure of the present invention's mixture acts as a binder material and the resulting products can be made water impermeable. Because of the durability of the present invention's binder in high temperature, the resulting products will also be of refractory nature.
  • the acid-base reaction that occurs in the coating of the present invention occurs, in one instance, between a phosphate anion (negative ion) and an aluminosilicate cations (positive ions), thereby forming an alumino-silico-phosphate coating product.
  • Part (Bl) and/or Part (B2) include, but are not limited to, unreactive silicates (such as sand), metals or metal oxides (e.g., titanium and/or a titanium oxide), aluminosilicates (marble and granite powder, silicate fibers and whiskers).
  • unreactive silicates such as sand
  • metals or metal oxides e.g., titanium and/or a titanium oxide
  • aluminosilicates marble and granite powder, silicate fibers and whiskers.
  • a coating in accordance with the present invention is produced by mixing one or more of Part (Al) and/or Part (A2) with one or more of Part (Bl) and/or Part (B2) at a ratio of Part (A1)/(A2) to Part (B1)/(B2) of about 1:0.5 to about 1:3, from about 1:0.75 to about 1:2.75, or even from about 1:1 to about 1:2.5.
  • a first initial thin layer of the coating of the present invention is sprayed onto a desired surface, say a layer having a thickness of about 1 mil to about 5 mils, then after 10 minutes another layer of the desired coating of the present invention is sprayed at a thickness of about 15 mils. Thereafter an additional amount of coating material can be applied at any desired thickness.
  • the coating of the present invention reacts with the substrate being sprayed and hardens into a hard coat with a thin passivation layer and a thick top protective coat within one hour.
  • any particles in any one or more of Part (Al), Part (A2), Part (Bl) and/or Part (B2) need to be as fine as possible.
  • the practical range is nano-particles of about 45 microns (i.e., particles passing through a 325 number sieve).
  • any particles used in any of Part (Al), Part (A2), Part (Bl) and/or Part (B2) are spherical and or nearly spherical in shape.
  • Part (Al) comprises:(Ala) from about 58 percent by weight to about 78 percent by weight of at least one alkali-acid phosphate or an equivalent thereof;(Alb) from about 1 percent by weight to about 5 percent by weight of phosphoric acid or an equivalent thereof; and(Alc) from about 17 percent by weight to about 37 percent by weight of water
  • Part (A2) comprises: (A2a) from about 5 percent by weight to about 17 percent by weight of at least one metal compound, metal oxide or an equivalent thereof;(A2b) from about 44 percent by weight to about 64 percent by weight of phosphoric acid or an equivalent thereof; and(A2c) from about 24 percent by weight to about 44 percent by weight of water.
  • a glass powder/metal oxide mixture is contemplated where the mixture consists of Part (Bl) or Part (B2), wherein Part (Bl) comprises:(Bla) from about 30 percent by weight to about 50 percent by weight of at least one silica-based glass powder or equivalent thereof;(Blb) from about 12 percent by weight to about 32 percent by weight of at least one metal oxide or an equivalent thereof; and(Blc) from about 23 percent by weight to about 43 percent by weight of water, andwherein Part (B2) comprises :(B2a) from about 12 percent by weight to about 32 percent by weight of at least one silica-based glass powder or equivalent thereof;(B2b) from about 30 percent by weight to about 50 percent by weight of at least one metal oxide or an equivalent thereof; and(B2c) from about 25 percent by weight to about 45 percent by weight of water.
  • This acidic phosphate and glass/powder metal oxide may be used separately or combined and further processed/used to produce coatings and compositions, all as disclosed herein.

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  • Ceramic Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
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Abstract

La présente invention concerne de manière générale des revêtements à base de silicate et des procédés de fabrication et d'application de ceux-ci. Dans un mode de réalisation, les revêtements de silicate de la présente invention sont formés à partir d'un mélange en deux parties d'un composant à base de phosphate et d'un composant à base de verre. Dans un autre mode de réalisation, les revêtements à base de silicate de la présente invention sont exempts de tout matériau organique.
PCT/US2021/018676 2020-02-19 2021-02-19 Revêtements à base de silicate pulvérisables et leurs procédés de fabrication et d'application WO2021168180A1 (fr)

Applications Claiming Priority (2)

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US16/795,094 US11565973B2 (en) 2016-04-06 2020-02-19 Sprayable silicate-based coatings and methods for making and applying same
US16/795,094 2020-02-19

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116656190A (zh) * 2022-12-31 2023-08-29 苏州弗克技术股份有限公司 一种单组分玻璃质基材用界面涂料及其制备方法

Citations (5)

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Publication number Priority date Publication date Assignee Title
US3248249A (en) * 1963-06-28 1966-04-26 Telefiex Inc Inorganic coating and bonding composition
JPS5324324A (en) * 1976-08-19 1978-03-07 Shingo Mizuno Coating composite
GB2180833A (en) * 1985-09-20 1987-04-08 G C Dental Ind Corp Fluoroaluminosilicate glass powder for dental glass ionomer cement
JPH01239049A (ja) * 1988-03-17 1989-09-25 Nissan Chem Ind Ltd 結合剤
WO2018193223A2 (fr) * 2017-03-14 2018-10-25 Michael Jackson Revêtements vitrocéramiques pulvérisables

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3248249A (en) * 1963-06-28 1966-04-26 Telefiex Inc Inorganic coating and bonding composition
JPS5324324A (en) * 1976-08-19 1978-03-07 Shingo Mizuno Coating composite
GB2180833A (en) * 1985-09-20 1987-04-08 G C Dental Ind Corp Fluoroaluminosilicate glass powder for dental glass ionomer cement
JPH01239049A (ja) * 1988-03-17 1989-09-25 Nissan Chem Ind Ltd 結合剤
US20190135681A1 (en) 2016-04-06 2019-05-09 Ceramicoat International Limited Sprayable alumino-silicate coatings, resins, their compositions and products
WO2018193223A2 (fr) * 2017-03-14 2018-10-25 Michael Jackson Revêtements vitrocéramiques pulvérisables

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116656190A (zh) * 2022-12-31 2023-08-29 苏州弗克技术股份有限公司 一种单组分玻璃质基材用界面涂料及其制备方法

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