Waterborne epoxy coating composition and method

Abstract

A waterborne coating composition comprising a waterborne epoxy coating with hydraulic cement, which is capable of a thin initial application. The coating composition may be made, stored and transported as a two-part composition, where each part is a pourable liquid. The waterborne epoxy composition cures under normal conditions and adheres to surfaces including masonry, concrete and metal.

1 . (canceled) 
   
   
       2 . A composition for use in coating surfaces with a thin coating, the composition comprising:
 (a) a desired amount of at least one epoxy resin;   (b) a desired amount of at least one mono glycidyl ether reactive diluent;   (c) a desired amount of at least one powdered hydraulic cement;   (d) at least one curing agent comprising a water soluble polyamine composition capable of emulsifying the epoxy resin;   (e) water in an amount at least sufficient to react with the powdered hydraulic cement; and   (f) wherein the composition forms coatings having a thickness of from approximately 2 mils to approximately 15 mils.   
   
   
       3 . The composition according to  claim 2 , wherein the epoxy resin is a liquid epoxy resin comprising approximately 11.0% to 19.0% by weight of the total composition. 
   
   
       4 . The composition according to  claim 3 , wherein the liquid epoxy resin is a liquid bisphenol A epoxy resin. 
   
   
       5 . The composition according to  claim 2 , wherein the powdered hydraulic cement is Portland Cement comprising approximately 30.0% to 70.0% by weight of the total composition. 
   
   
       6 . The composition according to  claim 2 , wherein the powdered hydraulic cement is a mixture of approximately 0.50 to 0.95 weight parts of Portland Cement and approximately 0.05 to 0.50 weight parts pozzolan powder derived from a group comprising fly ash, steel slag, silica fume, or calcined kaolin clay. 
   
   
       7 . The composition according to  claim 2 , wherein the curing agent is a polyamine having a plurality of N—H linkages capable of reacting with the epoxy resin comprising approximately 8.0% to 18.0% by weight of the total composition. 
   
   
       8 . The composition according to  claim 2 , wherein the curing agent is a polyoxyalkylene polyamine. 
   
   
       9 . The composition according to  claim 2 , wherein the curing agent is an arylene polyamine. 
   
   
       10 . The composition according to  claim 2 , wherein the curing agent is a cyclo-aliphatic polyamine. 
   
   
       11 . The composition according to  claim 2 , wherein the curing agent comprises a blend of a Mannich base with polyoxyalkylene polyamines, arylene polyamines, and cyclo-aliphatic polyamines. 
   
   
       12 . The composition according to  claim 2 , wherein the curing agent comprises a blend of polyoxyalkylene polyamines, arylene polyamines, and cyclo-aliphatic polyamines. 
   
   
       13 . The composition according to  claim 2 , wherein the composition further includes approximately 0.1% to 3.3% by weight of a non-reactive diluent. 
   
   
       14 . The composition according to  claim 13 , wherein the non-reactive diluent is benzyl alcohol. 
   
   
       15 . The composition according to  claim 13 , wherein the non-reactive diluent is an aromatic hydrocarbon resin. 
   
   
       16 . The composition according to  claim 2 , wherein the mono glycidyl ether is present in an amount of approximately 0.8% to 2.6% by weight of the composition. 
   
   
       17 . The composition according to  claim 16 , wherein the mono glycidyl ether is a C-6 to C-18 alkyl glycidyl ether. 
   
   
       18 . The composition according to  claim 16 , wherein the mono glycidyl ether is a C-12 to C-14 alkyl glycidyl ether. 
   
   
       19 . The composition according to  claim 2 , wherein the composition further includes approximately 6.0% to 24.0% by weight of a pigment. 
   
   
       20 . The composition according to  claim 19 , wherein the pigment is titanium dioxide. 
   
   
       21 . The composition according to  claim 2 , wherein the composition further includes approximately 0.08% to 0.26% by weight of an organosilicon adhesion promoter. 
   
   
       22 . The composition according to  claim 21 , wherein the organosilicon adhesion promoter is γ-glycidoxypropyl-trimethoxy silane. 
   
   
       23 . The composition according to  claim 2 , wherein the composition further includes approximately 4.0% to 31.0% by weight of a water-based latex resin. 
   
   
       24 . The composition according to  claim 23 , wherein the water-based latex resin is a styrene-acrylic latex. 
   
   
       25 . The composition according to  claim 23 , wherein the water-based latex resin is a styrene butadiene rubber latex. 
   
   
       26 . The composition according to  claim 23 , wherein the water-based latex resin is an acrylic latex. 
   
   
       27 . The composition according to  claim 2 , wherein the composition further includes hollow spheres in an amount of approximately 1.0% to 8.0% by weight of the composition. 
   
   
       28 . The composition according to  claim 2 , wherein the composition further includes approximately 0.15% to 0.55% by weight of a non-silicone defoamer. 
   
   
       29 . The composition according to  claim 2 , wherein the composition further includes approximately 0.15% to 0.55% by weight of a silicone defoamer. 
   
   
       30 . The composition according to  claim 2 , wherein the composition further includes approximately 0.01% to 2.4% by weight of a corrosion inhibitor 
   
   
       31 . The composition according to  claim 2 , wherein the composition forms coatings having a thickness of from approximately 4 mils to approximately 12 mils. 
   
   
       32 . The composition according to  claim 2 , wherein the composition forms coatings having a thickness of from approximately 6 mils to approximately 10 mils. 
   
   
       33 . A paint composition for use in coating surfaces, the composition comprising:
 (a) approximately 10% to 42% by weight of an epoxy resin;   (b) approximately 46% to 90% by weight of hydraulic cement powder;   (c) approximately 30% to 60% by weight of a curing agent comprising a water soluble polyamine composition capable of emulsifying the epoxy resin;   (d) water in an amount at least sufficient to react with the hydraulic cement;   (e) wherein the volatile organic compound content of the coating composition is not more than approximately 3.3% by weight of the total composition; and   (f) wherein the coating composition forms coatings having a thickness of from approximately 2 mils to approximately 15 mils.   
   
   
       34 . The composition according to  claim 33 , wherein the composition further includes a desired amount of an inert filler. 
   
   
       35 . The composition according to  claim 34 , wherein the inert filler comprises hollow spheres in an amount of approximately 1.0% to 8.0% by weight of the total composition. 
   
   
       36 . The composition according to  claim 33 , wherein the composition is applied to a surface using a brush, roller or airless sprayer to form a protective coating with a thickness of from approximately 6 mils to approximately 10 mils. 
   
   
       37 . The composition according to  claim 33 , having a gel time of approximately 60 to 120 minutes. 
   
   
       38 . The composition according to  claim 33 , having approximately 0.8 to 1.3 equivalents of total epoxy groups to 1.0 equivalent of reactive amine groups. 
   
   
       39 . The composition according to  claim 33 , having approximately 0.2 to 0.9 parts water to 1.0 part of hydraulic cement. 
   
   
       40 . A process for protecting a surface, the process comprising:
 (a) applying a fluid protective coating composition to the surface, the coating composition comprising:
 (i) a desired amount of at least one epoxy resin; 
 (ii) a desired amount of at least one mono glycidyl ether reactive diluent; 
 (iii) a desired amount of at least one powdered hydraulic cement; 
 (iv) at least one curing agent in an amount sufficient to react with the epoxy resin; and 
 (v) water in an amount at least sufficient to react with the powdered hydraulic cement; and 
   (b) permitting the coating composition to cure to form a protective coating with a thickness of from approximately 2 mils to approximately 15 mils.   
   
   
       41 . The process according to  claim 40 , wherein the composition is applied to a surface using a brush, roller or airless sprayer to form a protective coating with a thickness of from approximately 4 mils to approximately 12 mils. 
   
   
       42 . The process according to  claim 40 , wherein the composition is applied to a surface using a brush, roller or airless sprayer to form a protective coating with a thickness of from approximately 6 mils to approximately 10 mils. 
   
   
       43 . The process according to  claim 40 , wherein the composition is applied in two coats. 
   
   
       44 . The process according to  claim 40 , wherein the composition is applied in three coats. 
   
   
       45 . The process according to  claim 40 , wherein the composition further includes:
 (a) mixing approximately 90 parts epoxy resin with approximately 10 parts mono glycidyl ether reactive diluent;   (b) adding approximately 1 part hydraulic cement powder to approximately 0.11 to 1.15 part epoxy mixture; and   (c) adding approximately 1 part hollow spheres to approximately 3 to 50 parts of hydraulic cement powder to form a first component of said composition;   (d) separately mixing at least one curing agent, wherein the curing agent is a polyamine having a plurality of N—H linkages capable of reacting with the epoxy resin, with a desired amount of latex resin and water to form a second component of said composition; and   (e) combining the first component and the second component, in a ratio to provide a coating composition having approximately 0.8 to 1.3 equivalents of total epoxy groups to 1.0 equivalent of reactive amine groups, in a conventional airless sprayer.   
   
   
       46 . The process according to  claim 45 , wherein the first component and the second component are combined in a ratio to provide a coating composition having approximately 0.9 to 1.1 equivalents of total epoxy groups to 1.0 equivalent of reactive amine groups. 
   
   
       47 . The process according to  claim 45 , wherein the first component and the second component are combined in a ratio to provide a coating composition having approximately 0.2 to 0.9 parts water to 1.0 part of hydraulic cement. 
   
   
       48 . The process according to  claim 45 , wherein the first component and the second component are combined in a ratio to provide a coating composition having approximately 0.4 to 0.6 parts water to 1.0 part of hydraulic cement. 
   
   
       49 . A composition for use in coating surfaces with a thin coating, the composition comprising:
 (a) a desired amount of at least one epoxy resin;   (b) a desired amount of at least one powdered hydraulic cement;   (c) a desired amount of at least one type of hollow spheres;   (d) at least one curing agent in an amount sufficient to react with the epoxy resin;   (e) water in an amount at least sufficient to react with the powdered hydraulic cement;   (f) wherein the composition does not include a separate emulsifier surfactant; and   (g) wherein the composition forms coatings having a thickness of from approximately 2 mils to approximately 15 mils.   
   
   
       50 . A two-component composition for use in coating surfaces, the composition comprising:
 (a) a first component including:
 (i) approximately 10% to 42% by weight of an epoxy resin; and 
 (ii) approximately 46% to 90% by weight of hydraulic cement powder; and 
   (b) a second component including:
 (i) approximately 30% to 60% by weight of a curing agent; and 
 (ii) water in an amount at least sufficient to react with the hydraulic cement; and 
   (c) the first component and second component being mixed to provide the coating composition having a gel time of approximately 60 minutes to approximately 120 minutes, wherein the coating composition forms coatings having a thickness of from approximately 2 mils to approximately 15 mils.   
   
   
       51 . The composition according to  claim 50 , wherein the curing agent includes primary, secondary, and tertiary amine functionality. 
   
   
       52 . The composition according to  claim 50 , wherein the curing agent is a diamine. 
   
   
       53 . A two-component composition for use in coating surfaces, the composition comprising:
 (a) an aqueous first component including:
 (i) a desired amount of at least one water dispersed epoxy resin; 
 (ii) a desired amount of at least one latex resin; 
 (iii) a desired amount of water; and 
   (b) a non-aqueous second component including:
 (i) a desired amount of at least one liquid amine curing agent, wherein the curing agent is a polyamine having a plurality of N—H linkages capable of reacting with the epoxy resin; 
 (ii) a desired amount of at least one hydraulic cement powder; 
 (iii) a desired amount of at least one type of hollow spheres; and 
   (c) the first component and second component being mixed in a ratio to provide a coating composition having 0.20 to 0.90 parts water to 1.00 part of hydraulic cement, wherein the coating composition forms coatings having a thickness of from approximately 2 mils to approximately 15 mils.