US4209555A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Corrosion resistant galvanic coating
Assignee: AOS Holding Co
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Filing: 1979-01-26
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Granted: 1980-06-24
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Expires: 1999-01-26
Abstract
Abstract A coating of the inorganic zinc type which has, among other uses, excellent performance in the cathodic protection of metal from corrosion, especially when exposed to hot water. The coating is composed of mixture of zinc dust, extremely fine, high purity aluminum, sodium aluminum silicate and red iron oxide or titanium dioxide. Clay may be added for flow control and/or thixotrophy. The powder mixture is mixed with an alcoholic solution of partially hydrolyzed ethyl silicate liquid to form a slurry, and the slurry is thereafter sprayed or otherwise applied to a metal substrate to provide a coating having a thickness of 2 to 10 mils. Drying of the coating acts to evaporate the alcohol, and exposure to atmospheric humidity will fully hydrolyze the ethyl silicate to produce a dense, hard, tightly adherent coating which provides excellent corrosion resistance in a hot water environment.
Inventors
- 👤 Joe W. Stewart
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 18:32
CPC Classifications
C; C23; C23F; C23F13/00; C23F13/02; C09; C09D; C09D183/00; C09D183/02; C09D5/00; C09D5/08; C09D5/10
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
145 words
A protective coating composition to be applied to a metal substrate to cathodically protect the substrate when exposed to heated water, consisting essentially of (a) a dry finely divided mixture of 50-400 parts by weight zinc dust, 50-200 parts by weight of high purity aluminum powder, 50-150 parts by weight of sodium aluminum silicate, 1-5 parts by weight of a thixotrope, and a material selected from the group consisting of 1 to 10 parts by weight of iron oxide and 20 to 110 parts by weight titanium dioxide, and (b) a liquid, evaporable, non-aqueous carrier containing partially hydrolyzed ethyl silicate, said ethyl silicate being 70% to 90% hydrolyzed, said coating composition being dried after application to the metal substrate to evaporate the carrier and subsequent exposure to moisture acting to substantially fully hydrolyze the ethyl silicate to produce a hard adherent coating on said substrate.
Claim 2
Dependent Claim
145 words
A protective coating composition to be applied to a metal substrate to cathodically protect the substrate when exposed to heated water, consisting essentially of (a) a dry finely divided mixture of 50-400 parts by weight zinc dust, 50-200 parts by weight of high purity aluminum powder, 50-150 parts by weight of sodium aluminum silicate, 1-5 parts by weight of a thixotrope, and a material selected from the group consisting of 1 to 10 parts by weight of iron oxide and 20 to 110 parts by weight titanium dioxide, and (b) a liquid, evaporable, non-aqueous carrier containing partially hydrolyzed ethyl silicate, said ethyl silicate being 70% to 90% hydrolyzed, said coating composition being dried after application to the metal substrate to evaporate the carrier and subsequent exposure to moisture acting to substantially fully hydrolyze the ethyl silicate to produce a hard adherent coating on said substrate.
Claim 3
Dependent Claim
29 words
The composition of claim 1, wherein said composition contains 2.9 to 4.0 parts by weight of said mixture (a) to 0.9 to 1.5 parts by weight of said (b).
Claim 4
Dependent Claim
24 words
The composition of claim 1, wherein said carrier is ethyl alcohol and the ethyl silicate is dissolved in said alcohol to form a solution.
Claim 5
Dependent Claim
16 words
The composition of claim 3, wherein the solution contains approximately 66% by weight of said alcohol.
Claim 6
Dependent Claim
49 words
The composition of claim 1, wherein said zinc comprises 200 parts by weight, said aluminum comprises 100 parts by weight, said sodium aluminum silicate comprises 100 parts by weight, said material comprises 5 parts by weight of iron oxide and said thixotrope comprises 1-5 parts by weight of bentonite.
Claim 7
Dependent Claim
129 words
A protective coating composition to be applied to a ferrous substrate to cathodically protect the substrate, consisting essentially of (a) a dry finely divided mixture of 50-400 parts by weight zinc dust, 50-200 parts by weight of high purity aluminum powder, 50-150 parts by weight of sodium aluminum silicate, 1-5 parts by weight of a thixotrope, and a material selected from the group consisting of 1 to 10 parts by weight of iron oxide and 20 to 100 parts by weight of titanium dioxide, and (b) an ethyl alcohol solution having dissolved therein partially hydrolyzed ethyl silicate, said ethyl silicate being present in a weight ratio of 0.9 to 1.5 parts of ethyl silicate to 2.9-4.0 parts of said mixture (a), said ethyl silicate being 70% to 90% hydrolyzed.
Claim 8
Dependent Claim
129 words
A protective coating composition to be applied to a ferrous substrate to cathodically protect the substrate, consisting essentially of (a) a dry finely divided mixture of 50-400 parts by weight zinc dust, 50-200 parts by weight of high purity aluminum powder, 50-150 parts by weight of sodium aluminum silicate, 1-5 parts by weight of a thixotrope, and a material selected from the group consisting of 1 to 10 parts by weight of iron oxide and 20 to 100 parts by weight of titanium dioxide, and (b) an ethyl alcohol solution having dissolved therein partially hydrolyzed ethyl silicate, said ethyl silicate being present in a weight ratio of 0.9 to 1.5 parts of ethyl silicate to 2.9-4.0 parts of said mixture (a), said ethyl silicate being 70% to 90% hydrolyzed.
Claim 9
Dependent Claim
14 words
The composition of claim 6, wherein the ethyl silicate is 70% to 90% hydrolyzed.
Claim 10
Dependent Claim
16 words
The method of claim 6, wherein said coating has a thickness of 2 to 10 mils.
Claim 11
Independent Claim
156 words
A method of cathodically protecting a metal substrate from corrosion when exposed to heated water; comprising the steps of preparing a finely divided mixture consisting essentially of 50-400 parts by weight of zinc dust, 50-200 parts by weight of high purity aluminum powder, 50-150 parts by weight of sodium aluminum silicate, 1-5 parts by weight of a thixotrope, and a material selected from the group consisting of 1 to 10 parts by weight of iron oxide and 20 to 110 parts by weight of titanium dioxide to form a mixture; admixing a liquid, evaporable, non-aqueous carrier containing partially hydrolyzed ethyl silicate with the mixture to provide a slurry, said ethyl silicate being 70% to 90% hydrolyzed, applying the slurry to a surface of a metal substrate as a coating, drying the coating to evaporate the carrier, substantially fully hydrolyzing the ethyl silicate to provide a hard adherent coating, and thereafter exposing the coating to heated water.
Claim 12
Independent Claim
156 words
A method of cathodically protecting a metal substrate from corrosion when exposed to heated water; comprising the steps of preparing a finely divided mixture consisting essentially of 50-400 parts by weight of zinc dust, 50-200 parts by weight of high purity aluminum powder, 50-150 parts by weight of sodium aluminum silicate, 1-5 parts by weight of a thixotrope, and a material selected from the group consisting of 1 to 10 parts by weight of iron oxide and 20 to 110 parts by weight of titanium dioxide to form a mixture; admixing a liquid, evaporable, non-aqueous carrier containing partially hydrolyzed ethyl silicate with the mixture to provide a slurry, said ethyl silicate being 70% to 90% hydrolyzed, applying the slurry to a surface of a metal substrate as a coating, drying the coating to evaporate the carrier, substantially fully hydrolyzing the ethyl silicate to provide a hard adherent coating, and thereafter exposing the coating to heated water.
Claim 13
Dependent Claim
20 words
The method of claim 9, wherein the carrier is ethyl alcohol and said ethyl silicate is dissolved in said alcohol.
Claim 14
Dependent Claim
33 words
The method of claim 9, and including the step of preparing the surface of said substrate prior to applying the slurry thereto by blasting the surface with particulate material to roughen said surface.
Claim 15
Dependent Claim
13 words
The method of claim 9, wherein said slurry is sprayed on said surface.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-06-24 | 1983-12-24 | 1984-06-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-06-24 | 1987-12-24 | 1988-06-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-06-24 | 1991-12-24 | 1992-06-24 | $7700.00 | Window Closed / Lapsed |