SBIR Phase II: Polyaniline Epoxy Primer with Related Topcoat: the Anticorrosion Coating System of a Barrier to Cations with a Barrier to Anions

这个小企业创新研究（SBIR）第二阶段项目的更广泛的影响/商业潜力是将环氧基导电聚合物防腐涂料系统推向市场。2015年，腐蚀将使美国经济损失超过1万亿美元。开发更有效的防腐蚀技术以降低腐蚀的巨大经济成本是非常可取的。目前使用的最有效的防腐蚀颜料是基于重金属颜料，如铬酸盐、铅化合物和锌/锌化合物。环境、健康和安全问题正在推动消除重金属颜料。所提出的新产品不仅将减少当前重金属基防腐蚀颜料引入的毒性，而且还提供更好的腐蚀保护。该项目特别针对取代广泛用于公路，海洋和能源基础设施的环氧基富锌底漆涂料系统。解决环境友好型导电聚合物的加工性能差，应该能够开辟一系列新的应用范围以外的防腐蚀涂料，如静电耗散，电磁干扰屏蔽，抗静电纤维，导电油墨，调色剂，和粘合剂等拟议项目的智力价值在于使用先进的知识和防腐蚀涂料的理解。通常认为有机涂层在涂层-环境界面处充当水和氧的屏障。但金属的腐蚀是一个与阳离子和阴离子有关的电化学反应过程。本提案建议开发一种离子阻挡防腐蚀涂层体系：导电聚合物纳米粒子着色环氧底漆与面漆。底漆和面漆的组合构成了对阴离子和阳离子的屏障，其抑制电化学腐蚀反应，因此为金属提供了有效的腐蚀保护。该系统将不再使用重金属防腐颜料。如果目前提出的研究成功，它将展示离子阻挡涂层如何为金属基材提供腐蚀保护，以及如何配制离子阻挡防腐蚀涂层，并导致下一代防腐蚀涂层。

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase II project is in bringing epoxy based conductive polymer anticorrosion paint system to the market. Corrosion will cost the US economy over $1 trillion in 2015. It is highly desirable to develop more effective anticorrosion technologies to reduce this huge economic cost of corrosion. The most effective anticorrosion pigments in use today are based on heavy metal pigments, such as chromates, lead compounds, and zinc/zinc compounds. Environmental, health, and safety concerns are driving the elimination of heavy metal pigments. The proposed new product will not only reduce toxicity introduced by current heavy-metal based anti-corrosion pigments, but also provide much improved corrosion protection. The project is especially targeting replacement of the epoxy based zinc-rich primer coating systems that are widely used on highway, marine, and energy infrastructures. Solving the poor processibility of environmentally friendly conductive polymers should enable open up a range of new applications beyond anti-corrosion coatings such as electrostatic dissipation, electromagnetic interference shielding, static resistant fibers, conductive inks, toners, and adhesives, etc. The intellectual merit of the proposed project lies in using advanced knowledge and understanding of anticorrosion coatings. It is generally assumed that organic coatings act as barriers to water and oxygen at the coating - environment interface. But corrosion of metals is an electrochemical reaction process that relates to both cations and anions. The present proposal suggests developing an ion barrier anticorrosion coating system: conductive polymer nanoparticle pigmented epoxy primer with a topcoat. The combination of the primer and topcoat constructs a barrier to both anions and cations, that inhibits the electrochemical corrosion reaction, therefore, provides efficient corrosion protection to the metal. This system will not use heavy metal anticorrosion pigments any more. If present proposed research succeeds, it will demonstrate how an ion barrier coating provides corrosion protection to a metal substrate, and how to formulate an ion barrier anticorrosion coating, and lead to the next generation of anticorrosion coating.