Corrosion Inhibitors and Coating Compositions Containing the Same

Abstract

A corrosion inhibitor can include (a) an inorganic alkali and/or alkaline earth metal compound and (b) an aldehyde and/or ketone component comprising at least one aromatic ring comprising a ketone and/or aldehyde group and at least one pendant group represented by —OR1. Each R1 is independently selected from hydrogen, an alkyl group, or an aryl group. The coating composition can be used in a multi-layer coating with additional coating layers. Methods of preparing coating compositions with corrosion inhibitors and substrates at least partially coating with such compositions are also included.

The invention claimed is: 
     
         1 . An aircraft component comprising a coating composition applied over at least a portion of a surface of the component, the coating composition comprising:
 (a) a film-forming resin; and   (b) a corrosion inhibitor comprising: (i) at least one inorganic alkaline earth metal compound; and (ii) at least one aldehyde or ketone component,   wherein the aldehyde or ketone component comprises at least one aromatic ring in which the at least one aromatic ring comprises: (1) a ketone group, an aldehyde group, or a combination thereof, and (2) at least one pendant group represented by —OR 1 , wherein each R 1  is independently selected from hydrogen, an alkyl group, or an aryl group.   
     
     
         2 . The aircraft component of  claim 1 , wherein the inorganic alkaline earth metal compound comprises an inorganic alkaline earth metal salt. 
     
     
         3 . The aircraft component of  claim 1 , wherein the inorganic alkaline earth metal compound comprises an inorganic alkaline earth metal oxide or an alkaline earth metal hydroxide. 
     
     
         4 . The aircraft component of  claim 1 , wherein the inorganic alkaline earth metal compound comprises an inorganic magnesium compound. 
     
     
         5 . The aircraft of  claim 4 , wherein the inorganic alkaline earth metal compound comprises inorganic magnesium oxide or hydroxide. 
     
     
         6 . The aircraft component of  claim 1 , wherein the aromatic ring comprises at least two pendant groups represented by —OR 1 , wherein R 1  of a first pendant group is a hydrogen and R 1  of a second pendant group is an alkyl group. 
     
     
         7 . The aircraft component of  claim 1 , wherein the inorganic alkaline earth metal compound comprises inorganic magnesium oxide or hydroxide, and wherein the aromatic ring comprises at least two pendant groups represented by —OR 1 , wherein R 1  of a first pendant group is a hydrogen and R 1  of a second pendant group is an alkyl group. 
     
     
         8 . The aircraft component of  claim 7 , wherein the aldehyde and/or ketone component comprises 2-hydroxy-3-methoxy benzaldehyde. 
     
     
         9 . The aircraft component of  claim 1 , wherein a molar ratio of the aldehyde component or ketone component to the alkaline earth metal oxide or hydroxide is 2:1 or less. 
     
     
         10 . The aircraft component of  claim 1 , wherein the film-forming resin comprises a thermoplastic resin. 
     
     
         11 . The aircraft component of  claim 1 , wherein the film-forming resin comprises a thermoset resin. 
     
     
         12 . The aircraft component of  claim 11 , further comprising a crosslinking agent reactive with at least the film-forming resin. 
     
     
         13 . The aircraft component of  claim 1 , wherein the coating composition and/or corrosion inhibitor further comprises an alkoxysilane. 
     
     
         14 . The aircraft component of  claim 13 , wherein the alkoxysilane comprises an epoxy group, amino group, aryl group, vinyl group, alkyl group, or combinations thereof. 
     
     
         15 . The aircraft component of  claim 1 , wherein the coating composition and/or corrosion inhibitor further comprises an additional metal compound that is different from the inorganic alkaline earth metal compound. 
     
     
         16 . The aircraft of component  claim 1 , wherein the surface coated with the coating composition comprises a metallic material. 
     
     
         17 . The aircraft component of  claim 1 , wherein the coating composition is applied directly at least a portion of the surface as a mono-coat. 
     
     
         18 . The aircraft component of  claim 1 , wherein the coating composition is applied as a first coating layer over at least a portion of the surface and at least a second coating layer is applied over at least a portion of the first coating layer.