Electrically conductive coating compositions with corrosion resistance

Patent metadata

Field	Value
Publication number	US-11976216-B2
Application number	US-202117453789-A
Country	US
Kind code	B2
Filing date	Nov 5, 2021
Priority date	Aug 9, 2019
Publication date	May 7, 2024
Grant date	May 7, 2024

Abstract

An electrically conductive and corrosion resistant graphene-based coating composition, including a binder, high-pressure airless-sprayed expanded graphene stacks, carbon fibers, and a dispersing agent, wherein the graphene-based coating composition has an electrical conductivity of at least 2 S/cm and a pull-off adhesion of at least 2 MPa.

First claim

What is claimed is:

1. An electrically conductive and corrosion resistant graphene-based coating composition, comprising:
from about 50 weight % to about 99 weight % of a binder, based on a total weight of the graphene-based coating composition;
from about 7.0 weight % to about 16 weight % of a graphene filler, wherein the graphene filler comprises a plurality of high-pressure airless-sprayed expanded graphene stacks, each of the plurality of high-pressure airless-sprayed expanded graphene stacks having between 2 and 5 layers of graphene, based on a total weight of the binder in the graphene-based coating composition;
from about 0.10 weight % to about 5.0 weight % of electrically conductive components, wherein the electrically conductive components comprise carbon fibers, based on the total weight of the graphene-based coating composition; and
from about 0.10 weight % to about 5.0 weight % of a dispersing agent, based on the total weight of the graphene-based coating composition,
wherein the graphene-based coating composition has an electrical conductivity of at least 2 S/cm and a pull-off adhesion of at least 2 MPa.

2. The graphene-based coating composition of claim 1 , wherein the binder comprises an epoxy-based binder.

3. The graphene-based coating composition of claim 1 , wherein the binder consists essentially of an epoxy-based binder.

4. The graphene-based coating composition of claim 1 , wherein the graphene-based coating composition comprises from about 1.0 weight % to about 20 weight % of a combination of the graphene filler and the electrically conductive components, based on the total weight of the graphene-based coating composition.

5. An electrically conductive and corrosion resistant graphene-based coating composition, comprising:
from about 50 weight % to about 99 weight % of a binder;
from about 7 weight % to about 16 weight % of a graphene filler; and
a dispersing agent,
wherein the graphene filler comprises a plurality of high-pressure airless-sprayed expanded graphene stacks, each of the plurality of high-pressure airless-sprayed expanded graphene stacks has between 2 and 5 layers of graphene,
wherein the graphene-based coating composition has an electrical conductivity of at least 1 S/cm,
wherein the graphene-based coating composition has a pull-off adhesion of at least 2 MPa, and
wherein the graphene-based coating composition further comprises one or more electrically conductive components, wherein the one or more electrically conductive components comprise carbon fibers.

6. The graphene-based coating composition of claim 5 , wherein the plurality of high-pressure airless-sprayed expanded graphene stacks are at least partially exfoliated, and
wherein the graphene-based coating composition has an electrical conductivity of at least 2 S/cm.

7. The graphene-based coating composition of claim 5 , wherein the graphene filler consists essentially of high-pressure airless-sprayed expanded graphene stacks.

8. The graphene-based coating composition of claim 5 , wherein the graphene filler consists essentially of a plurality of high-pressure airless-sprayed expanded graphene stacks.

9. The graphene-based coating composition of claim 5 , comprising from about 0.10 weight % to about 5.0 weight % of the dispersing agent.

10. The graphene-based coating composition of claim 5 , wherein the dispersing agent comprises an alkylammonium salt of a high molecular-weight copolymer.

11. The graphene-based coating composition of claim 5 , wherein the binder comprises an epoxy-based binder.

12. The graphene-based coating composition of claim 5 , wherein the binder consists essentially of an epoxy-based binder.

13. The graphene-based coating composition of claim 5 , further comprising the carbon fibers at a weight ratio of graphene-filler to carbon fibers in a range of about 0.1:10 to 1:5.

14. The graphene-based coating composition of claim 5 , further comprising at least one of a carrier, additional dispersion aids, surface treatment agents, adhesion promoters, thickening agents, defoamers, hardeners, wetting agents, cross-linking agents, curing agents, flow enhancers, viscosity agents, and stabilizers.

15. The graphene-based coating composition of claim 5 , wherein the graphene-based coating composition has an electrical conductivity of at least 5 S/cm.

16. The graphene-based coating composition of claim 5 , wherein the graphene-based coating composition has a pull-off adhesion of at least 5 MPa.

17. The graphene-based coating composition of claim 5 , wherein the graphene-based coating composition that extends corrosion protection to steel or aluminum alloys for more than 50 hours in a neutral salt spray test.

18. The graphene-based coating composition of claim 5 , wherein the graphene-based coating composition comprises from about 1.0 weight % to about 20 weight % of a combination of the graphene filler and the one or more electrically conductive components, based on the total weight of the graphene-based coating composition.

Assignees

• Boeing Co

Inventors

• Ijeri Vijaykumar S
• Gaydos Stephen P
• Kinlen Patrick J
• Dhirde Priyanka G
• Khanna Anand

Classifications

• C09D5/24 Primary

  Electrically-conducting paints {(conductive materials H01B1/00)} · CPC title

• C09D5/08

  Anti-corrosive paints · CPC title

• C09D7/61

  inorganic · CPC title

• C09D163/00

  Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins · CPC title

• H01B1/04

  mainly consisting of carbon-silicon compounds, carbon or silicon · CPC title