Nanocomposite conformal corrosion barrier coating

Patent metadata

Field	Value
Publication number	US-10150873-B2
Application number	US-201816008994-A
Country	US
Kind code	B2
Filing date	Jun 14, 2018
Priority date	May 26, 2016
Publication date	Dec 11, 2018
Grant date	Dec 11, 2018

Abstract

Metals across all industries demand anti-corrosion surface treatments and drive a continual need for high-performing and low-cost coatings. Ordered thin films comprising aligned inorganic platelets dispersed in a polyelectrolyte polymer matrix provide a new class of transparent conformal barrier coatings for protection in corrosive atmospheres. For example, films assembled via layer-by-layer deposition, as thin as 90 nm, are shown to reduce copper corrosion rates by >1000× in an aggressive H 2 S atmosphere. These coatings can provide high-performing anti-corrosion treatment alternatives to costlier, more toxic, and less scalable thin films, such as graphene, hexavalent chromium, or atomic layer deposited metal oxides.

First claim

We claim:

1. A corrosion barrier coating, comprising at least one layer of dispersed and aligned inorganic platelets in a polyelectrolyte polymer matrix deposited on a corrodible metal substrate.

2. The coating of claim 1 , wherein the inorganic platelets comprise clay platelets.

3. The coating of claim 2 , wherein the clay platelets comprise montmorillonite, vermiculite, or laponite.

4. The coating of claim 1 , wherein the inorganic platelets comprise alumina, graphene, graphene oxide, boron nitride, or a layered double hydroxide.

5. The coating of claim 1 , wherein the at least one layer of dispersed and aligned inorganic platelets in a polyelectrolyte polymer matrix comprises a layer of dispersed and aligned clay particles deposited on a polyelectrolyte polymer layer.

6. The coating of claim 5 , wherein the clay platelets are anionic and the polyelectrolyte polymer layer comprises a cationic polymer layer.

7. The coating of claim 6 , wherein the cationic polymer comprises polyethyleneimine or ethylene vinyl amine.

8. The coating of claim 6 , wherein the polyelectrolyte polymer layer further comprises an anionic polymer layer.

9. The coating of claim 8 , wherein the anionic polymer comprises poly(acrylic acid).

10. The coating of claim 1 , wherein the at least one layer of dispersed and aligned inorganic platelets in a polyelectrolyte polymer matrix comprises at least one quadlayer, each quadlayer comprising a layer of montmorillonite deposited on a polyelectrolyte layer, the polyelectrolyte layer comprising a layer of polyethyleneimine deposited on a layer of poly(acrylic acid) deposited on a layer of polyethyleneimine.

11. The coating of claim 10 , wherein the corrosion barrier coating comprises at least six quadlayers.

12. The coating of claim 5 , wherein the clay platelets are anionic and the polyelectrolyte polymer layer comprises a cationic polymer layer.

13. The coating of claim 1 , wherein the at least one layer of dispersed and aligned inorganic platelets in a polyelectrolyte polymer matrix is deposited by a layer-by-layer deposition process.

14. The coating of claim 1 , wherein the corrodible metal substrate comprises copper.

15. The coating of claim 1 , wherein the corrodible metal substrate comprises steel, brass, bronze, iron, zinc, aluminum, magnesium, silver, nickel, and alloys thereof.

Assignees

• Nat Tech & Eng Solutions Sandia Llc
• Grunlan Jaime C
• Texas A & M Univ Sys

Inventors

• Schindelholz Eric John
• Spoerke Erik David
• Sorensen Neil R
• Grunlan Jaime C

Classifications

• C09D179/02

  Polyamines · CPC title

• C09D133/02

  Homopolymers or copolymers of acids; Metal or ammonium salts thereof · CPC title

• C09D139/02

  Homopolymers or copolymers of vinylamine · CPC title

• C09D5/08 Primary

  Anti-corrosive paints · CPC title

• C08K3/346

  Clay · CPC title