Polyolefin thermoset anti-corrosion coatings

 
Polyolefin thermoset (PT) coatings based on Proxxima resins consisting of cyclic alkene monomers dicyclopentadiene (DCPD) and tricyclopentadiene (TCPD), exhibit unique performance attributes as a new class of anti-corrosion coatings. Rapid ring-opening metathesis polymerization (ROMP) of these cyclic alkene monomers using 2nd generation ruthenium-based Grubbs catalysts significantly reduces the cure time and offers fast return-to-service benefits. The inherent hydrophobic nature of these polyolefin coatings makes them good candidates for anti-corrosion coating applications. The new resins are 100% resin solids with a very low viscosity, which enables formulating low VOC sprayable coatings with high level of inorganic fillers. The carbon footprint of product (CFP) of Proxxima resin is significantly lower than other chemistries typically used in coating industry, which further provides sustainability benefit. Polyolefin thermoset coatings exhibit high toughness, good impact resistance, excellent 95°C hot water immersion performance as well as ASTM B117 salt spray and AMPP TM21442-2023 CUI cyclic testing. Rapid return-to-service benefit has been demonstrated with polyolefin thermoset coating formulations paired with fast-reacting catalyst and a commercial plural component spray equipment. A thick coating (40 mil) can be readily accomplished in a single coat without dripping or sagging and a dry-to-touch time in less than 10 minutes was achieved. The resin chemistry can also be blended with other chemistries to formulate novel PT/Epoxy and PT/PU hybrid coatings to form interpenetrating polymer networks (IPN) with synergistic benefits. The hybrid coatings can be formulated with suitable work-life and applied via conventional airless spray equipment. The resin and its hybrid technology has found good applications in corrosion under insulation (CUI), marine cargo lining, and railcar exterior coating, etc.