Method of providing a high opacity, thin coat line-marking paint on airport runways

Abstract: The present invention provides a high opacity thin coat concept airport runway marking paint comprising 20-60% by weight of titanium dioxide in the paint or higher to within the critical pigment volume concentration (C.P.V.C.), extenders such as Barium Sulphate, Laminar Talc, Calcite or Dolomite used alone or as blends thereof, binders such as Placticised Chlorinated Rubber, Acrylated rubber, Epoxy, Polyurethane or emulsified resins and an anti-skid aggregate comprising crushed glass particles or calcined Aluminium oxide or the like. The high opacity paint has the advantage that it can be sprayed on at very thin film thickness thereby minimising the tendency of the build up of thick smooth film to potentially hazardous levels.

Description: The present invention relates to a method of providing a high opacity, thin coat concept line-marking paint on airport runways particularly on aircraft runways. US 2,574,971 discloses quick drying highway marking paints adapted to be sprayed on highway surfaces so as to provide durable reflex light reflective traffic markers which have high night time visibility to motorists. The specification of US 2,574,971 also discloses a beaded type of highway surface marker which involves only a single step application procedure since the paint and admixed beads are simultaneously coated on the highway surface. The specification of US 3,005,790 discloses a reflective highway marking paint comprising a paint vehicle containing between about 0.5 lb. and about 8 lbs. of a suspended mixture of glass particles per gallon of glass-free paint. The glass particles are a mixture of transparent glass beads having an average diameter of the order of about 3 to about 10 mils and glass fragments of a size to be retained by a U.S. Standard No. 270 mesh screen and being constituted by a plurality of angularly intersecting substantially planar light reflecting faces, the ratio of said glass beads to glass fragments being in the range between 2:1 and 1:8, and said fragments being present in sufficient concentrations such that when applied to a highway as a marking paint the fragments provide with the binder a keying action whereby dislodgement of fragments and spheres is resisted. The specification of US Patent No. Re 30,463 discloses ambient drying traffic paint compositions and methods for their application comprising a resin binder and pigment(s) in a three-component or four-component solvent system, in parts by weight of : boiling point 190-141°F 5-11 boiling point 140-106°F 12-17 boiling point 105-90°F 2-[28]28.99 boiling point greater than 225°F 0-12 The disclosed compositions are applied at ambient temperatures without the use of external heating means and a relatively fast drying time of about 20 to 60 seconds is obtained. Aircraft runways generally have white line-markings applied intermittently on the centre along the entire of their length and also a continuous line along each side. Usually, these lines are approximately one metre wide. In addition, there are intermittent large "block" markings outlining the touch-down zone at each end of the runway. These markings are necessary in order to provide clear visibility of the runway and to assist a pilot in calculating distance factors for "touch down" and "take off" of his aircraft. There is a requirement that runway surfaces be tested for skid-resistance and therefore most modern runways have a specially designed "friction course" on the runway in order to comply with safety regulations. It follows that the white-line paint markings should not affect the inherent safety features of the runway surface. Conventional public road-marking paints are often used in the application of white line markings to runways. Sometimes these conventional paints incorporate spherical glass beads. The beads which are included at the application stage of such conventional road paints are used in order to increase light reflectance which is desirable from the point of view of a motorist but not necessarily from a pilot's point of view. In fact, the presence of such beads in runway line-markings has the disadvantage that it results in a low-friction factor on the paint coating which may induce a skid with potentially serious adverse consequences. Conventional road-marking paints are generally formulated with the intention that they will be applied as a relatively thick film. A typical roadway paint formulation contains rather low levels of Titanium dioxide, approximately 10-16% weight of Titanium dioxide to total weight of paint . The dry film thickness is usually specified by paint manufacturers as being between 150 microns and 300 microns following spray application. The dry film thickness of conventional road markings in many urban areas can be as high as 2000 microns, the emphasis being on the provision of durable, thick coats. This comparatively high dry film thickness is used on roads in order to obtain high durability against the eroding effects of traffic and harsh weather conditions. However, runway markings generally need frequent re-application in any case because of blackening caused by the aircraft tyres. This "black soiling" problem occurs long before the paint has eroded and frequent re-application is necessary in order to maintain the high level of whiteness and visibility expected of such markings. It has been found at some airports that centreline maintenance repainting was necessary every two to four weeks due to the "black soiling" problem caused by a heavy volume of aircraft traffic. Thus, the use on aircraft runways of conventional road marking paints which are formulated primarily with different design requirements in mind has the disadvantage that frequent re-application results in the line thickness rapidly building up to an unacceptably high level. This has the added disadvantage that cracking and spalling of thick coatings then occurs and also causes the line to develop a smooth slippery surface. The present invention seeks to alleviate the disadvantages associated with known paints used on airport runways. The present invention accordingly provides a method of providing a high opacity, thin coat line-marking paint on airport runways characterised by applying a paint comprising at least one binder and an opacifying white pigment in a concentration range, the lower limit of which is 20% w/w, weight of pigment to total weight of paint, and the upper limit of which is determined by being adequately bound and within the critical pigment volume concentration of the paint and further characterised in that when the paint is applied, there is provided a single coat of the paint having a dry film thickness which is sufficient to obliterate blackening ("black soiling") caused by aircraft tyres. The present invention further provides a method of providing a high opacity, thin coat line-marking paint on airport runways characterised by applying a paint comprising at least one binder and an opacifying white pigment in a concentration range, the lower limit of which is 20% w/w, weight of pigment to total weight of paint, and the upper limit of which is determined by being adequately bound and within the critical pigment volume concentration of the paint and further characterised in that when the paint is applied, there is provided a single coat of the paint having a dry film thickness which is in the range of from 30 to 45 microns. Ideally, the opacifying white pigment is titanium dioxide. Preferably, the paint includes an anti-skid aggregate comprising crushed glass particles or calcined aluminium oxide. Conveniently, the binders include any one of the following group; Plasticised Chlorinated Rubber, Acrylated Rubber, Epoxy Resin, Polyurethane Resin, emulsified resin. The binder is preferably based on a durable plasticised chlorinated rubber medium, (unmodified, non-convertible type). Advantageously, the binder concentration is related to a nominal pigment volume concentration (P.V.C.) range of between 48% and 55% which is within the critical pigment volume concentration (C.P.V.C.). The paint may also include an extender comprising Barium Sulphate, Laminar Talc, Calcite or Dolomite, or a blend thereof (Calcite/Dolomite are present in a maximum concentration of 10% in the paint). Preferably the white pigment used is Titanium dioxide, and is included in the formulation as a good commercial grade Rutile form of the pigment having a minimum of 97% weight of Titanium dioxide to weight of pigment; the balance being made up with suitable surface treatments. In a preferred embodiment, the concentration of white pigment in the paint is between 20 and 60% w/w. The concentration of white pigment in the paint is preferably between 30% and 35% w/w based on the total weight of paint. However, the invention also allows for higher opacity versions of the paint, preferably containing 45% to 50% w/w white pigment. The special high opacity feature allows the paint to be applied as an exceptionally thin maintenance coating, which in turn confers material cost savings and also improved safety and technical features. A thin film (approximately 40-45 microns dry film thickness) of the high opacity paint is sufficient to just obliterate "black soiling". Advantageously, a thin film of approximately 30-35 microns (dry film thickness ) can be applied with suitable obliterating properties if a higher opacity version of the paint according to the invention is used. The high opacity paint according to the invention has good adhesion to a substrate, good intercoat adhesion and also good cohesion within "compound coatings" of itself, up to approximately 2000 microns (dry film thickness). Preferably, the crushed glass particles comprising the anti-skid additive aggregate are colourless and the calcined Aluminium oxide is white or near white in the dry state. Advantageously, the particle size range of the glass particles or Calcined Aluminium oxide may be between 150-300 microns. Alternatively the particle size of the glass particles or calcined aluminium oxide may be in the range 300-600 microns. The rate of addition of the anti-skid additive in the line markings is 1-2 kgs per 5 litres of paint, added on certain occasions of repainting only. The high opacity paint according to the invention, advantageously comprises a solvent system which allows for very quick drying of the paint (approximately 2 minutes dry). This has the advantage that maintenance work can be carried out very quickly and results in minimal interference to flight schedules at busy airports. Furthermore, the quick drying characteristic of the high opacity paint allows maintenance work to be carried out even when uncertain weather condition prevail. In one embodiment, the solvent system comprises Butan-2-one (known in Industry as Methyl Ethyl Ketone) and Toluene. In a separate embodiment, the solvent system comprises solvents such as 3,3-Dimethyl butan-2-one (also known as Methyl Isobutyl Ketone) and Xylene for slower evaporation which may be required in hot climatic conditions. The paint according to the invention may comprise additives such as strongly polar solvents which facilitate paint application to damp (not wet) surfaces. The solvent system thus confers some tolerance to surface dampness (not wet) due to the polar solvent content. Other speciality chemicals may be included for surface dampness conditions. Such speciality chemicals are known for the purpose and are commercially available. In each of the above embodiments, the high opacity paint has substantially the same properties such as viscosity, rheology and P.V.C. The viscosity of a typical formulation is 0.65-0.70 Pa.s (6.5-7.0 Poises) as measured on the ICI Rotothinner* viscometer at 25°C. The paint according to the invention has thixotropic or mild gel characteristics in order to preclude pigment settlement during storage. The paint is formulated such that it is suitable for application by existing spray machinery. Advantageously, precision-film-thickness spray application machinery such as Hofmann's Amokos* system may be employed. For spray application purposes, thinners may be included in the amount of 25% v/v and comprise blends of the solvents already included in the formulation and in the same proportions. The thinners, should be included in the paint formulation just before application to the runway surface. It has been found that paint according to the invention, when sprayed correctly at very thin films, minimises the tendency for rapid build up of thick smooth films to potentially hazardous levels, and thus that the paint lines do not detract from the required friction standards of the runway. Use of the paint according to the invention has substantial economic advantage since only about one third of the film thickness of many conventional road line-marking coatings is required. The material cost per litre of the proposed paint is marginally higher than that of "conventional" road marking paint due to the "high opacity" formulation of the former, but this material cost is very much offset by savings accrued as a result of much lower volume usage. The invention will now be described more particularly with reference to the following non-restrictive examples: EXAMPLE 1 COMPOSITION % by weight Titanium Dioxide Pigment: 30%-35% (preferred Rutile Type 97% min. Tio 2 ) MINERAL EXTENDER PIGMENTS: 18%-22% such as Barium Sulphate, Laminar Talc, Calcite or Dolomite, either alone or as blends thereof. (Calcite/Dolomite max. 10% in paint) BINDER (SOLIDS) 18%-21% Plasticised Chlorinated Rubber preferred Typical Composition; Ratio I.C.I. "Alloprene" R10 1.00 to 1.50 I.C.I. Cereclor 70 0.50 I.C.I. Cereclor 48 0.50 or approved equivalents VOLATILE/SOLVENTS SYSTEM 28%-32% Composition; Ratio Methyl Ethyl Ketone 1.00 Toluene 2.00 ADDITIVES Surfactant/wetting Agent: e.g. Lecithin 0.25-0.50% Structuring/suspending agent; e.g. Bentone 27 or/and Armogel 0.50-1.00% Acid Stabilizer/Epoxidised Soya Oil e.g. Edenol D81 1.00% ANTI-SKID AGGREGATE ; i.e. Crushed Colourless Glass Particles (Typical sizes) a. Sizes within the particle-size range of 150 up to 300 microns. or b. As above within the size range of 300 up to 600 microns. OR ALTERNATIVELY; c. Calcined Aluminium Oxide (white or near white) (typica sizes) 150 up to 300 microns particle range. or d. Calcined Aluminium Oxide (white or near white), within the Particle size range of 300 up to 600 microns. EXAMPLE 2. (for use in hot climatic conditions) COMPOSITION % by weight Titanium Dioxide Pigment: 30%-35% (preferred Rutile Type 97% min. TiO 2 ) MINERAL EXTENDER PIGMENTS: 18%-22% such as Barium Sulphate, Laminar Talc, Calcite or Dolomite, either alone or as blends thereof. (Calcite/Dolomite max. 10% in paint) BINDER (SOLIDS) 18%-21% Plasticised Chlorinated Rubber preferred Typical Composition; Ratio I.C.I. "Alloprene" R10 1.00 to 1.50 I.C.I. Cereclor 70 0.50 I.C.I. Cereclor 48 0.50 (or approved equivalents) VOLATILE/SOLVENTS SYSTEM 28%-32% Such as; Ratio Methyl IsoButyl ketone 1.00 Xylene 2.00 ADDITIVES Surfactant/wetting Agent: e.g. Lecithin 0.25-0.50% Structuring/suspending agent; e.g. Bentone 27 or/and Armogel 0.50-1.00% Acid Stabilizer/Epoxidised Soya Oil e.g. Edenol D81 1.00% ANTI-SKID AGGREGATE; i.e. Crushed Colourless Glass Particles (Typical sizes) a. Sizes within the particle-size range of 150 up to 300 microns or b. As above within the size range of 300 up to 600 microns OR ALTERNATIVELY; c. Calcined Aluminium Oxide (white or near white) (typical sizes) 150 up to 300 microns particle range. or d. Calcined Aluminium Oxide (white or near white), within the Particle size range of 300 up to 600 microns. EXAMPLE 3 COMPOSITION % by weight Titanium Dioxide Pigment: 45-50% (preferred Rutile Type 97% min. TiO 2 ) MINERAL EXTENDER PIGMENTS: 5-15% such as Barium Sulphate, Laminar Talc, Calcite or Dolomite, either alone or as blends thereof. (Calcite/Dolomite max. 10% in paint) BINDER (SOLIDS) 18%-21% Plasticised Chlorinated Rubber preferred Typical Composition; Ratio I.C.I. "Alloprene" R10 1.00 to 1.50 I.C.I. Cereclor 70 0.50 I.C.I. Cereclor 48 0.50 VOLATILE/SOLVENTS SYSTEM 28%-32% Composition; Ratio Methyl Ethyl Ketone 1.00 Toluene 2.00 ADDITIVES Surfactant/wetting Agent: e.g. Lecithin 0.25-0.50% Structuring/suspending agent; e.g. Bentone 27 or/and Armogel 0.50-1.00% Acid Stabilizer/Epoxidised Soya Oil e.g. Edenol D81 1.00% ANTI-SKID AGGREGATE ; i.e. Crushed Colourless Glass Particles (Typical sizes) a. Sizes within the particle-size range of 150 up to 300 microns. or b. As above within the size range of 300 up to 600 microns. OR ALTERNATIVELY; c. Calcined Aluminium Oxide (white or near white) (typical sizes) 150 up to 300 microns particle range. or d. Calcined Aluminium Oxide (white or near white), within the Particle size range of 300 up to 600 microns. EXAMPLE 4 (for use in hot climatic conditions) COMPOSITION % by weight Titanium Dioxide Pigment: 45%-50% (preferred Rutile Type 97% min. TiO 2 ) MINERAL EXTENDER PIGMENTS: 5%-15% such as Barium Sulphate, Laminar Talc, Calcite or Dolomite, either alone or as blends thereof. (Calcite/Dolomite max. 10% in paint) BINDER (SOLIDS) 18%-21% Plasticised Chlorinated Rubber preferred Typical Composition; Ratio I.C.I. "Alloprene" R10 1.00 to 1.50 I.C.I. Cereclor 70 0.50 I.C.I. Cereclor 48 0.50 VOLATILE/SOLVENTS SYSTEM 28%-32% Such as; Ratio Methyl IsoButyl ketone 1.00 Toluene 2.00 ADDITIVES Surfactant/wetting Agent: e.g. Lecithin 0.25-0.50% Structuring/suspending agent; e.g. Bentone 27 or/and Armogel 0.50-1.00% Acid Stabilizer/Epoxidised Soya Oil e.g. Edenol D81 1.00% ANTI-SKID AGGREGATE; i.e. Crushed Colourless Glass Particles (Typical sizes) a. Sizes within the particle-size range of 150 up to 300 microns. or b. As above within the size range of 300 up to 600 microns. OR ALTERNATIVES; c. Calcined Aluminium Oxide (white or near white) (typical sizes) 150 up to 300 microns particle range. or d. Calcined Aluminium Oxide (white or near white), within the Particle size range of 300 up to 600 microns.

Claims: A method of providing a high opacity, thin coat line-marking paint on airport runways characterised by applying a paint comprising at least one binder and an opacifying white pigment in a concentration range, the lower limit of which is 20% w/w, weight of pigment to total weight of paint, and the upper limit of which is determined by being adequately bound and within the critical pigment volume concentration of the paint and further characterised in that when the paint is applied, there is provided a single coat of the paint having a dry film thickness which is sufficient to obliterate blackening ("black soiling") caused by aircraft tyres. A method according to claim 1, further characterised in that the paint includes an anti-skid aggregate which comprises crushed glass particles or calcined aluminium oxide. A method according to claim 1, characterised in that the concentration of opacifying white pigment in the paint is between 20 and 60% w/w. A method according to claim 3, characterised in that the concentration of opacifying white pigment in the paint is between 30 and 35% w/w. A method according to claim 3, characterised in that the concentration of opacifying white pigment is between 45 and 50% w/w. A method according to any of claims 2 to 5, characterised in that the opacifying white pigment is Titanium Dioxide. A method according to any of claims 2 to 6, characterised in that the paint includes a solvent system comprising butan-2-one and toluene. A method according to any of claims 2 to 6, characterised in that the paint includes a solvent system comprising 3,3-dimethyl butan-2-one and xylene. A method according to any of claims 2 to 8, characterised in that the paint includes a binder which is selected from the group consisting of: plasticised chlorinated rubber, acrylated rubber, epoxy resin, polyurethane resin, emulsified resin. A method according to any of claims 2 to 9, characterised in that the paint includes a mineral extender pigment selected from the group consisting of: barium sulphate, laminar talc, Calcite or Dolomite or a blend thereof (Calcite/Dolomite are present in a maximum concentration of 10% in the paint). A method of providing a high opacity, thin coat line-marking paint on airport runways characterised by applying a paint comprising at least one binder and an opacifying white pigment in a concentration range, the lower limit of which is 20% w/w, weight of pigment to total weight of paint, and the upper limit of which is determined by being adequately bound and within the critical pigment volume concentration of the paint and further characterised in that when the paint is applied, there is provided a single coat of the paint having a dry film thickness which is in the range of from 30 to 45 microns.

Inventors: COUGHLAN THOMAS NOEL, COUGHLAN, THOMAS NOEL
Applicants: COUGHLAN THOMAS NOEL, COUGHLAN, THOMAS NOEL
Application year: 1991
Main classification: C09D5
IPC codes: C09D5