Use of a top coat paint for protection from external rust-staining

Abstract: A top coat paint for protecting a surface from exter­ nal rust-staining comprises a film-forming binder and a solid substance having a water solubility of at least 0.1 gram per litre and capable of reacting with rust. The substance capable of reacting with rust is capable of chelating iron and has a high formation constant for complexation with Fe(III). The chelate complex formed with Fe(III) is substantially colourless and no less water-­ soluble than the said substance. The said substance is (a) a salt of a substituted aliphatic organic acid or of a 1,3-diketone, or (b) an aliphatic hydroxamic acid of the formula where R is an alkyl group of 1 to 18 carbon atoms, or a salt thereof. It may be produced by mixing the ingredients.

Description: This invention relates to the use of a top coat paint for protecting surfaces from external rust-staining such as surfaces of structures exposed to the atmosphere, for example buildings, ships and bridges, and surfaces of construction materials which are to be used at the exterior of such structures. Paints are applied to buildings and other structures exposed to the atmosphere in order to give protection against the weather and for decorative effect. Unfortunately, the appearance of the painted building is often rapidly marred by external rust-staining. The term "external rust-staining" is used herein to mean the discoloration of a surface due to contact from the outside with rust as opposed to discoloration from a source of rust beneath the surface in the underlying substrate. The rust may be from a source external to the surface, for example water containing rust in the form of dissolved corrosion products falling onto or flowing down the surface. Iron and steel pipework, guttering and girders and other construction members may have considerable surface rust whilst still structurally sound. When it rains, rust in the form of dissolved corrosion products drips onto any surfaces below and causes an ugly brown stain which is very difficult to remove. The rust may be from an isolated damage site on the surface, causing a brown stain on the intact paint below the damage site. One area where this causes particular problems is on the superstructure of ships and the upper part of the topside of ships' hulls, particularly for passenger ships such as cruise liners and ferries. These may become externally rust-stained soon after repainting. Examples of rust sources on ships are isolated damage sites, for example where the anchor chains strike the hull, and inaccessible parts of the superstructure which may be left unpainted. The paint of the present invention inhibits such external rust-staining. GB-A-2172599 describes a process for inhibiting external rust-staining on a surface by painting the surface with a top coat paint comprising a film-forming binder and a substance capable of reacting with rust to form a colourless material. The substance can for example be a polyphosphonate salt pigment, an oxalate or a glass releasing phosphate ions. EP-A-209231 describes a water-based coating for ferrous substrates and containing a carboxylic acid such as oxalic, lactic or tartaric acid to prevent "flash rusting", that is staining of the coating as it dries by rust arising from the ferrous substrate. EP-A-O,023,371 discloses coating compositions that may be applied under water. These compositions comprise a film-forming resin, a complexing agent forming a complex with an oxidised iron surface, and a non-reactive solvent which is partly soluble in water. Examples of the complexing agent include aliphatic, aromatic and heterocyclic mono- and polycarboxylic acids; adducts of maleic acid or its anhydride with olefins, thiols or primary or secondary amines; 1,3-diketones; N-hydroxyimides; aliphatic, cycloaliphatic, vinyl, allyl, benzyl or aromatic hydroxamic acids; and hydroxyquinoline or benzoxazine or their derivatives. The complexing agent reacts with the ferrous hydroxide that is formed when an iron surface is cleaned or with the iron surface itself. The complexing agent is soluble in the coating composition, whereas it is only weakly soluble in water. The complex formed after application of the coating composition is preferably non-hydrophilic, not containing any water, and should be compatible with the dry coating layer. EP-A-0,037,442 discloses corrosion-inhibiting compositions which comprise 5-95% by weight of a barium salt of a carbonyl group-containing organic compound having at least one acidic hydroxy hydrogen. Representative of such compounds are substantially water-insoluble hydrous and anhydrous barium salts of organic acids, saturated, ethylenically unsaturated, or aromatic. The carbonyl groups may be present as carboxy ester, carboxyl, aldo, keto or amido groups. These corrosion-inhibiting compositions can be applied directly to the bare metal or over an adhesion-promoting primer. The paints of GB-A-2172599 have proved effective in inhibiting brown stains caused by rust. However, the colourless material formed by reaction of the substances described in GB-A-2172599 with rust is in general not water-soluble and a white deposit may be formed towards the end of the lifetime of the paint. Whilst its presence is not noticeable in white and lightly coloured paints it may be noticeable in deeply coloured paints. The present invention provides an improved paint for inhibiting external rust-staining. According to the present invention there is provided the use of a top coat paint for protecting a surface from external rust-staining, comprising a film-forming binder and a solid substance having a water-solubility of at least 0.1 gram per litre and capable of reacting with rust, characterised in that the substance capable of reacting with rust is capable of chelating iron and has a high formation constant for complexation with Fe(III), the chelate complex formed with Fe(III) being substantially colourless and remaining substantially colourless over prolonged periods of time and being no less water-soluble than the said substance, the said substance being (a) a salt of an aliphatic carboxylic acid substituted by a hydroxy, amine, hydroxyamine, thiol, keto, aldehyde or oxime group, or (b) a salt of a 1,3-diketone, or (c) an aliphatic hydroxamic acid of the formula in which R is an alkyl group of 1 to 18 carbon atoms. By "a substance capable of reacting with rust" is meant a substance capable of reacting with water-borne iron corrosion products which form solid rust (ferric oxide) on drying in air. The invention also includes a process for protecting a surface from external rust-staining, characterised in that a top coat paint as defined above is applied to the external surface of a structure or to a construction material intended for use at the external surface of a structure. The term "structure" is used to include ships as well as land-based structures. The surface of the ship or other structure or of the construction material which is to be protected from external rust-staining may for example be of metal, wood, brick, concrete, plaster, plastics or fibre board. By a "top coat paint" is meant a paint which is intended to be exposed in use, that is it is not to be overcoated. When the paint is applied to a non-metallic surface, for example masonry such as brick or concrete, it may be the only coating applied to the surface, whereas when it is applied to metal it is generally applied over a primer. Such a primer is generally one containing an anticorrosive pigment but it does not usually contain a substance capable of reacting with rust to form a colourless or soluble material. The substance capable of reacting with rust preferably has a formation constant for complexation with Fe(III) greater than 10²⁰ moles⁻¹. This refers to the first formation constant. In the case of salts as the substance capable of reacting with rust it refers to the anionic form, that is to say it is the equilibrium constant for the reaction where L x- is the anion of the salt. The water-solubility of the substance is generally 0.1 to 50g/l and is preferably 0.2 to 10 g/l for a matt paint and 0.4 to 20 g/l for a gloss paint. The water-solubility figures are measured at a temperature of 20°C. The most preferred substance capable of reacting with rust is a salt of a carboxylic acid having a substituent which increases its chelating power for iron. The salt is usually a salt of a metal which is at least di-valent, for example a calcium, zinc, manganese, magnesium, barium or aluminium salt. The substituent in the acid which increases its chelating power is a hydroxy, amine, hydroxamine, thiol, keto, aldehyde or oxime group. The salt is preferably a salt of a hydroxy-substituted carboxylic acid, particularly an acid having an alpha-hydroxy group such as citric, tartaric or lactic acid. Examples of salts of amine-substituted carboxylic acids are salts of nitrilo-triacetic acid N(CH₂COOH)₃ or iminodiacetic acid HN(CH₂COOH)₂. Calcium salts, for example calcium tartrate or calcium citrate, are particularly preferred. Barium citrate and zinc citrate are other examples of preferred salts. The salt should preferably not be highly coloured, and salts of the preferred metals mentioned above are in general not highly coloured. Alternative salts are salts of a 1,3-diketone, for example the zinc or calcium salt of an aliphatic 1,3-diketone having 5 to 10 carbon atoms such as 2,4-pentane-dione. Such salts are generally chelated complex salts but the divalent metal ions generally have a lower formation constant for complexation with diketones than Fe(III) does. The substance capable of reacting with rust can alternatively be a hydroxamic acid of the formula where R is an alkyl group of 1-18 carbon atoms. The hydroxamic acids are very weak acids; even if a salt of hydroxamic acid is used it may exist mainly in the free acid and free base form. The hydroxamic acids are solids. Aceto-hydroxamic acid is an example, although it is more water-soluble than the preferred range and should not be used at a high pigment volume concentration. Higher alkyl hydroxamic acids are less water-soluble. Since the substance capable of reacting with rust which is used according to the present invention forms a complex with Fe(III) which is no less water-soluble than the salt itself, no precipitate is formed on the surface of the paint film. This gives an advantage in appearance; the complex is not noticeable in any colour paint and does not reduce the gloss of the paint. GB-A-2172599 suggests the use of oxalate salts or salts of a polycarboxylic derivative of a polyamine such as ethylene diamine tetraacetic acid. We have found that in these cases the iron complex, although initially colourless, is light-sensitive so that there is a possibility of discoloration causing a visible blemish. especially in light coloured paints. By contrast, paints according to the present invention appear to remain substantially colourless over prolonged periods of time. The use of the top coat paint defined above in accordance with the present invention has substantial advantages in cost and convenience over the use of traditional anti-corrosive paints in preventing rust-staining. With traditional methods all the layers of paint have been removed in the area where rust-staining has occurred and the metal surface has been cleaned of rust and then painted with an anti-corrosive primer and a top coat paint. The top coat paint defined above in accordance with the present invention can be applied over existing coats of paint, thereby hiding existing rust-staining and inhibiting further rust-staining. Alternatively, if the rust-staining emanates from an isolated damage site in the coated surface itself, the position and extent of damage is more easily seen and the coating system can be repaired in a limited area. The pigment volume concentration of the paint is preferably at least 25 per cent. The solid substance capable of reacting with rust is regarded as part of the pigment of the paint. Top coat paints for metal surfaces preferably have a pigment volume concentration of 25 - 40 per cent; this is higher than that of conventional gloss top coat paints but allows the paint to have some sheen. Paints for concrete and other masonry preferably have a pigment volume concentration of 40 - 55 per cent. The rate of release of the active salt from the paint by contact with moisture increases as the total pigment volume concentration (PVC) of the paint increases. In particular the rate of release increases sharply with PVC as the PVC rises above 30 per cent and especially above 35 per cent. The substance capable of reacting with rust is generally used as 2 - 70 per cent by volume of the total pigment in the paint. Preferably it constitutes 5 - 35 per cent by volume of the total solids content of the paint. The remainder of the total pigment can be an inert pigment, for example of the type conventionally used in exterior paints, e.g. titanium dioxide or a colouring pigment such as a phthalocyanine. The film-forming binder for the top coat paint defined above in accordance with the present invention can in general be any of those used in the paint industry, for example an alkyd resin (including modified alkyds), an epoxy resin (including epoxy esters), an oleoresin, a chlorinated rubber, a vinyl resin, a polyurethane, a polyether, an organic or inorganic silicate, a polyamide or an acrylic polymer. Two or more compatible film-forming organic polymers can be used in the paint. An extender resin such as a hydrocarbon resin can be present. A plasticiser for the binder resin, for example a chlorinated paraffin or a low molecular weight resin such as an acrylic resin or a polybutene, may be used. A preferred binder for a masonry paint is for example an acrylic polymer such as a copolymer of one or more alkyl acrylates and methacrylates, preferably a styrene/acrylic copolymer containing 25 - 75 per cent by weight acrylic ester units and 25 - 75 per cent styrene units. Top coat paints for use over a primer on metallic structures can for example use such an acrylic binder, preferably a styrene/ acrylic ester copolymer and/or an alkyd resin. The presence of a plasticiser is highly preferred with such styrene/acrylic copolymers. The rate of release from the paint by contact with moisture of the substance capable of reacting with rust increases with increasing plasticiser content of the paint, particularly at high plasticiser levels. For example, at a PVC of 35 per cent the rate of release increases significantly as the plasticiser level increases above 25 per cent by volume of total polymer plus plasticiser, and it more than doubles as the proportion of plasticiser increases from 30 to 40 per cent by volume. The top coat paint defined above in accordance with the present invention is preferably applied from solution in an organic solvent. The solvent is chosen having regard to the nature of the film-forming binder and plasticiser if used and can for example be an aromatic hydrocarbon and/or an aliphatic hydrocarbon. The paint can alternatively be applied from an emulsion, for example using an acrylic emulsion polymer binder. The paint is generally applied by spray, brush or roller. Alternatively the paint can be a coil coating to be applied as a plastisol or hot melt or a powder coating to be applied by electrostatic spray, for example to cladding which is to be used at the exterior surface of a building. The invention is illustrated by the following examples of top coat paints to be applied over a primer to a metal surface. The paints can be prepared by conventional paintmixing techniques. Examples Substance Description Example 1 Example 2 Example 3 Vol Wt Vol Wt Vol Wt Calcium citrate Ca₃(C₆H₅O₇)₂.4H₂O 7.9 14.1 - - - - Zinc citrate Zn₃(C₆H₅O₇)₂.2H₂O - - 8.2 14.2 - - Calcium tartrate CaC₄H₄O₆.4H₂O - - - - 7.8 13.2 Rutile Titanium dioxide 4.02 14.8 4.02 14.9 5.53 19.5 Bentone 38 Organo clay gellant 0.30 0.50 0.32 0.53 0.30 0.48 Plasticising resin 5.88 5.65 6.85 6.61 7.0 6.44 Pliolite Styrene/acrylic ester copolymer 16.9 16.3 15.5 15.0 14.3 13.2 Solvents Petroleum naphtha and white spirit 65.0 48.7 65.1 48.8 65.0 47.2

Claims: Use of a top coat paint for protecting a surface from external rust-staining, comprising a film-forming binder and a solid substance having a water-solubility of at least 0.1 gram per litre and capable of reacting with rust, characterised in that the substance capable of reacting with rust is capable of chelating iron and has a high formation constant for complexation with Fe(III), the chelate formed with Fe(III) being substantially colourless and remaining substantially colourless over prolonged periods of time and being no less water-soluble than the said substance, the said substance being (a) a salt of an aliphatic carboxylic acid substituted by a hydroxy, amine, hydroxyamine, thiol, keto, aldehyde or oxime group, or (b) a salt of a 1,3-diketone, or (c) an aliphatic hydroxamic acid of the formula in which R is an alkyl group of 1 to 18 carbon atoms. The use according to claim 1, characterised in that the salt is a citrate, tartrate or lactate. The use according to claim 1 or 2, characterised in that the salt is a calcium salt. The use according to claim 1 or 2, characterised in that the salt is a zinc, manganese, magnesium, barium or aluminium salt. The use according to claim 1, characterised in that the substance capable of reacting with rust is a salt of 2, 4-pentanedione. The use according to claim 1, characterised in that the substance capable of reacting with rust is an aliphatic hydroxamic acid of the formula given in claim 1 in which R is an alkyl group of 2 to 18 carbon atoms. The use according to claim 1, characterised in that the substance capable of reacting with rust has a formation constant for complexation with Fe(III) greater than 10²⁰ mole ⁻¹. The use according to any of claims 1 to 7 characterised by the presence of a pigment volume concentration of 25% to 55% in the paint, the substance capable of reacting with rust being counted as a pigment for the purposes of the pigment volume concentration. The use according to claim 8, characterised in that the substance capable of reacting with rust has a water-solubility of 0.4 to 20 grams per litre and the paint has a pigment volume concentration of 25% to 40%. The use according to claim 8, characterised in that the substance capable of reacting with rust has a water-solubility of 0.2 to 10 grams per litre and the paint has a pigment volume concentration of 35% to 55%. The use according to any of claims 8 to 10, characterised in that the substance capable of reacting with rust is used as 5% to 35% by volume of the total solids content of the paint. The use according to any of claims 1 to 11, characterised in that the film-forming binder contained in the paint is an acrylic polymer. The use according to claim 12, characterised in that the acrylic polymer is a plasticised styrene acrylic ester copolymer. A process for protecting a surface from external rust-staining, characterised in that a top coat paint as defined in any of claims 1 to 13 is applied to the external surface of a structure exposed to the atmosphere or to a construction material intended for use at the external surface of a structure exposed to the atmosphere. A process according to claim 14, characterised in that the surface is a metal surface which has previously been coated. A process according to claim 14, characterised in that the surface is a wood, brick, concrete, plaster, plastics or fibre-board surface.

Inventors: HANDYSIDE TIMOTHY MARC, SINCLAIR-DAY JOHN DAVID, HANDYSIDE, TIMOTHY MARC, SINCLAIR-DAY, JOHN DAVID
Applicants: COURTAULDS COATINGS HOLDINGS, COURTAULDS COATINGS (HOLDINGS) LIMITED
Application year: 1989
Main classification: C09D5
IPC codes: C09D133, C09D5, C09D7