Note: Descriptions are shown in the official language in which they were submitted.
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IMPROVED COATINGS MADE WITH TRINIDAD
LAKE ASPHALT
RELATED APPLICATIONS
The instant application hereby claims the benefit of the filing date of U.S.
Provisional Application Serial No. 60/055,097 filed August 6, 1997, and U.S.
Provisional Application Serial No. 60/064,099 filed November 3, 1997.
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of coatings, and, more
particularly, to improved coatings which incorporate Trinidad Lake Asphalt as
a
raw material therein.
Coatings, such as paints, primers, sealers, epoxies, roofing compounds,
sound deadeners, road markings, membranes, and the like, have for many years
been manufactured using a variety of base materials as well as in combination
with other specific materials. Some of these base materials or base materials
including other materials have not been environmentally friendly. For example,
epoxies, which have stood the test of time and have proven to be useful for
many
applications, are generally coal tar based or plastic based, with the coal tar
based
epoxies being widely accepted as carcinogenic.
Due to environmental concerns, manufacturers of such coatings are now
attempting to use raw materials, which would give the same performance and, in
addition, would be more environmentally friendly. However, to date, there has
been no suitable substitutes for these raw materials which have been
considered
to provide satisfactory coating products. Thus, many environmentally
unfriendly
coating products are still being widely used.
Thus, a need exists for improved coating products which overcome the
disadvantages of the prior art.
CONFIRMATION COPY
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SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide
improved coating products, including, but not limited to, paints, primers,
sealers,
epoxies, roofing compounds, sound deadeners, road markings, membranes and any
other suitable coating products.
A further object of the present invention is to provide improved coating
products which have at least as good or better performance characteristics as
prior
art coatings and, in addition, are more environmentally friendly.
Another object of the instant invention is to provide improved coating
products which advantageously use Trinidad Lake Asphalt, also known as
Trinidad Natural Asphalt or Epure, as a raw material in said coating products.
Yet another object of the instant invention is to provide improved coatings
which are resistant to, among other things, petroleum distillates, aromatic
solvents,
salt water immersion, an electric current, acids and alkalis.
A further object of the invention is to provide improved coatings which
are unaffected by, among other things, exposure to fresh water, deionized
water
systems, distilled water systems, bromides, chlorides and sulphate.
A further object of the instant invention is to provide coatings having
improved durability, flexibility, resistance to abrasion, resistance to an
applied
force, resistance to aromatic solvents and/or enhanced aesthetics.
Yet another object of the instant invention is to provide improved coatings
which can be used in low altitude and low temperature environments without
degradation.
A more specific object of the instant invention is to provide an improved
epoxy product, an improved sealant product, such as a seam sealant, an
improved
roofing compound product, and improved undercoating/sound deadener product,
and improved water tank paint, an improved chassis black product, and improved
zinc primer black product, an improved zinc primer grey product, an improved
road marking coating product, an improved coating which has a dry film
thickness of 2 mil. or greater which is also termed a membrane, as well as
other
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types of improved coating products, all of which advantageously incorporate
Trinidad Lake Asphalt as a raw material therein.
Yet another object of the instant invention is to make coatings using non-
molten mixers (e.g. Banbury, high shear internal mixers, etc.) instead of
molten
mixers (heaters, etc.) for the purpose of mixing the Trinidad Lake Asphalt and
at
least one other raw material.
These and other objects and advantages are achieved by the present
invention, which provides improved coating products, all of which include at
least
some Trinidad Lake Asphalt therein as well as at least one other raw/modifying
material.
Other features, objects and advantages of the subject invention will
become apparent from a study of the following specification which describes
preferred applications and embodiments of the instant invention and is not to
be
interpreted as limiting the scope of the instant invention beyond the true
scope of
the appended claims herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Trinidad Lake Asphalt {hereafter "TLA"), also known as Trinidad Natural
Asphalt or Epure, is a naturally occurring Lake Asphalt which is found in the
island of Trinidad in the West Indies. This natural phenomenon, TLA, is
different from and is not to be confused with tar sands, or tar pits or even
asphalt
which is a natural or mechanical mixture in which bitumen is associated with
mineral matter. An accepted definition which has been given to TLA is: an
asphalt which, as found in nature, is in a condition of flow or fluidity.
As dug from the earth, TLA contains thirty percent (30%) water which is
- normally be removed through refining under conditions of temperature. The
molten material is then filtered and sometimes packed into silicone treated
hardboard drums. The drums are typically silicone treated as the temperature
at
which the molten TLA is filled into the drum is generally around 163°C.
Prior to the instant invention, TLA has been used only in paving or road
building materials and applications. In accordance with the instant invention,
it
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has now been discovered that TLA can be used as a component of many different
types of coatings to improve the characteristics and/or performance thereof,
with
new and unexpected results.
More particularly, the instant inventor has discovered that TLA can
advantageously be used as a raw material to make a variety of coating products
in order to provide an environmentally friendly product with improved
characteristics. As used herein, the term coatings is meant to have a broad
meaning and to include, but not be limited to, paints, primers, sealers,
epoxies,
roofing compounds, underbody coating/sound deadener, road markings,
membranes, and any other similar or suitable coatings whether expressly
referenced herein or not.
In its broadest sense, the instant invention is directed to the use of TLA
as a raw material in the manufacture of any coating. More particularly, the
invention involves coatings made by combining TLA and at least one other
known type of raw material, such as solid carriers (e.g., carbon fibers,
etc.),
and/or liquid carriers (e.g. water, alcohol, etc.) and/or gaseous carriers
(polar
gases, non-polar gases, etc.), and/or anything which modifies TLA from its
natural state.
In accordance with a preferred embodiment of the instant invention, many
coatings can be made using some or all of the following elements in the range
(percent by weight) indicated below, in conjunction with the TLA:
TLA 1 % to 99%
Polymers/Co-Polymers 1 % to 99%
Carrier 1 % to 99%
Clay 1% to 95%
Pigment 1% to 95%
Carbonaceous material 1% to 95%
Resins 1 % to 99%
The carrier may be any suitable solid and/or liquid and/or gaseous
material. For example, as described in further detail below, the carrier,
could be
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a petroleum distillate, such as White Spirit and/or Methylated Spirit and/or
water.
The carbonaceous material may be, for example, fibre (natural or synthetic),
carbon black (both for reinforcing and colorant) or charcoal (activated or non-
activated). The clay may be, for example, a material known as Claytone 40
and/or silica. The resin may be, for example, a polyamide, such as the product
known as Epon 813 Resin, and/or a epichlonolydrin/bisphenol A, such as the
product known as Versamid 115 Resin and/or water. The polymers/co-polymers
may be, for example, rubber.
More specific examples of particular coating products made in accordance
with the instant invention will now be described in detail below, along with
general information on the preferred uses for such products, the
characteristics
thereof and exemplary processes for making such products. It is to be
understood, however, that the examples below are considered to be preferred
embodiments of the invention and that various changes and/or modifications
could
be made thereto, as one skilled in the art will understand, without deviating
from
the scope of the instant invention.
EPOXY PRODUCT EXAMPLE
The following is an example of a two part epoxy system made in
accordance with one embodiment of the instant invention. A variety of improved
epoxy products can be made using the following elements in the ranges (percent
by weight) set forth below:
TLA 1 % to 60%
Polymers/Co-Polymers 1 % to 60%
Carrier 1 % to 60%
Clay 1 % to 60%
Resins 1 % to 80%
In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the epoxy product may be as follows:
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TLA 19.79
White Spirit 11.61
Claytone 40 1.85
Methylated Spirit 0.53
Toluene 4.75
Rubber 0.26
Silica 6.07
Epon 813 Resin 27.44
Versamid 115 Resin 27.70
It is noted that in this embodiment, all of the elements,
except Epon 813
Resin form the first part of the two part epoxy system.
The Epon 813 Resin is
used as the second part of the epoxy system.
A preferred process for making this epoxy is as follows:
1) Claytone 40 is stirred with White Spirit to form a slurry
and
poured into a blending tank;
2) TLA is crushed in a pulveriser into sizes of 1 "-2".
It is then
weighed and fed into the heating tank. This is heated to
140 degrees C - 150
degrees C. In the molten state this is poured into the blending
tank and blended
for 10 minutes;
3) The rubber which was pre-weighed and dissolved by stirring
with
50% of the toluene is then added at this stage. Blend for
approximately 20
minutes; reaction/bonding must occur;
4) Silica is added at this stage;
5) The methylated spirit is poured into the blending tank
to complete
blending;
6) The product is then fed through the vibratory screen
of sizes 25
mesh and 80 mesh;
7) The filtered product is cooled to 30 C-35C. Versamid
115-resin
is blended in to give a uniform consistency and re-filtered
through the 25 mesh
and 80 mesh filters;
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8) The blending tank is jacketed to allow a cooling solution to flow
through during the blending process; The temperature of finished product:
50°
C-60° C
9) The Epon 813 Resin is then used as the second part of the epoxy
system;
The epoxy described herein, provides a colorless or colored, rubberized or
non-rubberized, two part epoxy system. The complete TLA may be used which
means that no black has to be removed from the material in order for it to be
pigmented to any color or for it to remain colorless. Further, the amount of
Pigment required is less than twenty percent (20%) of the complete
formulation.
This epoxy can be made into all relevant colors and may also remain colorless.
All the inherent properties which are present in the solvent "based" epoxies
inclusive of drying times, are retained.
Additional information, in the form of a data sheet, regarding
characteristics and usage of this exemplary epoxy product are set forth below.
This amide cured two part epoxy dries to an extremely hard finish of
differing flexibilities and can be used in harsh environments. It contains no
coal
tar, is non-carcinogenic, and is environmentally sound. It is natural asphalt
based
and the coating provides maximum protection to metal surfaces, and has
outstanding low moisture-vapor transmission. It also contains no heavy metals,
e.g., mercury, lead or vanadium, but does contain a high percentage of
titanium.
PETROLEUM PRODUCTS . Resistant to sour crudes and
lubricating oils.
ALKALI RESISTANCE . Very resistant to mild alkalis and
_ can be used as a tank lining for
aggressive solutions such as 20%
caustic, 10% calcium hydroxide,
10% ammonia and 10% potassium
hydroxide.
ACID RESISTANCE . Unaffected by most common acids,
e.g., 15% hydrochloric acid, 25%
sulfuric acid and 20% nitric acid.
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SEA WATER . Unaffected by complete sea
immersion and sea blast.
Also,
unaffected by fresh water,
deionized/distilled water
systems,
bromides, chlorides, sulfates,
etc.
PRIMING . Usual epoxy primers
SURFACE PREPARATION . Sand blasting, white metal
blasting
where metal has been previously
coated or severe corrosion
has
occurred, or as specified
by The
Society for Protective Coatings.
SHELF LIFE . Indefinite, once properly
covered.
DENSITY' OF FINISHED . 9.17 lb./gal.
PRODUCT
FLASH POINT . Above 140F
V.O.C. . 20%
BINDER CONTENT . 80%
SOLVENT . 20%
SOLIDS CONTENTS . 80%
FINISH . Gloss
COLOR . Black
COVERAGE . 88 sq. ft./gal at 8 mil.
Dry Film
Thickness
DRYING TIME . 6-8 HOURS
MIXING RATIO . 1:1 BASE TO CATALYST AS
SUPPLIED
NUMBER OF COATS . Two 4 mil. coats
APPLICATION . Brush, spray and roll-on.
POT LIFE : 3 hours at ambient temperature
SALT SPRAY . No deterioration of panels
*rB
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CLEAN UP . Vinegar, immediately after use
TEMPERATURE RESISTANCE : 212° F (panel immersed in boiling
water)
SEALANT COATING EXAMPLE
The following is an example of a sealant product made in accordance with
one embodiment of the instant invention. A variety of improved sealant
products
can be made using the following elements in the approximate ranges (percent by
weight) set forth below:
TLA 1 % to 99%
Polymers/Co-Polymers 1 % to 60%
Carrier 1 % to 60%
Clay I % to 60%
In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the sealant product may be as follows:
Percentage by weight of raw materials
TLA 75.52
White Spirit 12.86
Claytone 40 2.70
Methylated Spirit 0.83
Toluene 7.26
Rubber 0.83
A preferred process for making this product is as follows:
1. Claytone 40 is stirred with the white spirit to form a slurry and
poured into a blending tank.
*rB
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2. TLA is crushed in a pulveriser into sizes of 1 "-2". It is then
weighed and fed into the heating tank. This is heated to 140 degree C - 150
degree C. In the molten state this is poured into the blending tank and
blended
for 10 minutes.
3. The rubber which was pre-weighed and dissolved by stirring with
the toluene is then added at this stage. Blend for approximately 20 minutes.
Reaction/bonding must occur.
4. Finally the methylated spirit is poured into the tank and blending
is completed with a uniform consistency.
5. The product is then fed through a vibratory screener of sizes 25
mesh and 80 mesh for a finished product. Blending tank is jacketed to allow a
cooling solution to flow through during the blending process. Temperature of
finished product: 50° C-60° C.
Additional information, in the form of a data sheet, regarding
I S characteristics and usage of this exemplary sealant product are set forth
below:
GENERIC TYPE : Non-sag rubberized natural asphalt
sealant
RECOMMENDED USES . Sealing leaks of drinking water
tanks, (metal and concrete)
cementing down asphalt shingles,
repairing cracks in concrete walls or
in old roofs. Can also be used for
sealing internal joints and seams in
_ vehicular bodies. If it is to be used
extensively on a roof then it is
recommended that the area be
covered with Surecoat's Roofing
Compound Grey. Use extensively in
built-up roofing systems.
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GENERAL PROPERTIES . A black natural asphalt
cement
containing a special rubber
blend. It
will adhere to any dry surface.
CHEMICAL RESISTANCE : Resistant to splashes from
all
petroleum solvents e.g.,
gasoline,
diesel fuel, etc. Just allow
area to
dry and film is back to
normal. DO
NOT wipe area.
TEMPERATURE . Can be stoved up to 150
C for 30
mins.
SURFACE PREPARATION . Surface must be dry
PRIMING . Concrete surfaces must first
be
sealed off using, for example,
Surecoat's Concrete Sealant.
1 S THINNING & CLEAN-UP : Surecoat #AP3 Reducer
TOP COAT REQUIRED . Not necessary
APPLICATION : Brush, spray or roll-on
SPECIFICATIONS
SOLIDS CONTENT : 85-90%
DRY FILM THICKNESS . 400 um (per coat)
COVERAGE . 4 sq. meter/liter (100 sq. ft./US
gal);
might be more or less depending
on
use e.g., size of cracks, etc.
SHELF LIFE . Indefinite
COLOR : Black
APPLICATION : Ambient
TEMPERATURE
DRYING TIME . Touch dry 1-2 hours. Complete
drying 24-36 hours. Can be painted
over after 24 hours
VISCOSITY : 320-330 (25 C Penetration Cone)
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FLASH POINT . 37° C
WEIGHT PER US GALLON . 3.80 kg (8.37 lb.)
ROOFING COMPOUND EXAMPLE
The following is an example of a roofing compound product made in
accordance with one embodiment of the instant invention. A variety of improved
roofing compound products can be made using the following elements in the
approximate ranges (percent by weight) set forth below:
TLA 1 % to 90%
Polymers/Co-Polymers 1 % to 60%
Carrier 1 % to 60%
Clay 1 % to 60%
Pigment 1 % to 80%
In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the roofing compound product may be as follows:
Percentage by weight of raw materials
Trinidad Natural Asphalt 43.88
White Spirit 24.70
Claytone 40 3.84
Methylated Spirit 1.20
Toluene 11.51
Rubber 0.72
Titanium Dioxide Pigment 14.15
A preferred process for making this product is as follows:
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1. Claytone 40 is stirred with 40% of the white spirit to form a slurry
and poured into a blending tank.
2. Asphalt is crushed in a pulveriser into sizes of 1 "-2". It is then
weighed and fed into the heating tank. This is heated to 140 degrees C - 150
degrees C. In the molten state this is poured into the blending tank and
blended
for approximately 10 minutes.
3. Remaining toluene and white spirit solvents are pumped into the
blending tank at this stage.
4. The rubber which was pre-weighed and dissolved by stirring with
50% of the toluene is then added at this stage. Blend for approximately 20
minutes. Reaction/bonding must occur.
5. Titanium dioxide pigment is then added at this stage.
6. Finally the methylated spirit is poured into the blending tank to
give a uniform consistency.
7. The product is then fed through the vibratory screen of sizes 25
mesh and 80 mesh for a finished product.
8. The blending tank is jacketed to allow a cooling solution to flow
through during the blending process. Temperature of finished product:
50° C-
60° C.
Additional information, in the form of a data sheet, regarding
characteristics and usage of this exemplary roofing compound product are set
forth below:
SURFACE PREPARATION : For new galvanize:
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1) Degrease
2) Apply each primer and leave
for 1-2 hours
3) Use Surecoat Zinc Chromate
Primer and then Roofing
Compound
For old galvanize:
1 ) Remove all rust with a wire
brush and follow (2) and {3)
above.
COMPONENT : One pack
COVERAGE . 15 sq. meter/US gallon
APPLICATION . Brush, spray or roll-on
DRY FILM THICKNESS . 130-140 microns
SPECIFICATIONS
SOLIDS CONTENT . 68-70%
SPECIFIC GRAVITY : 1.14
DRYING TIME . 1 hour
FLASH POINT . 37 C
APPLICATION . Brush or spray
COLOR . Bone grey
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RECOMMENDED USES . All types of metallic and bituminous
based roofs (e.g., shingles)
THINNING & CLEAN-UP . Surecoat #AP4 Reducer
UNDERBODY COATING/SOUND DEADENER EXAMPLE
The following is an example of a underbody coating/sound deadener
product made in accordance with one embodiment of the instant invention. A
variety of improved underbody coating/sound deadener products can be made
using the following elements in the approximate ranges (percent by weight) set
forth below:
TLA 1 % to 90%
Polymers/Co-Polymers 1% to 60%
Carrier 1 % to 60%
Clay 1 % to 60%
In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the underbody coating/sound deadener product may
be as follows:
Percentage by weight of Raw Materials:
Trinidad Natural Asphalt 58.63
White Spirit 13.65
- Claytone 40 1.41
Methylated Spirit 0.40
Toluene 7.63
Rubber 0.60
Silica Flour 17.67
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A preferred process for making this product is as follows:
1. ~ Claytone 40 is stirred with 40% of the white spirit to form a slurry
and poured into blending tank.
2. Asphalt is crushed in a pulveriser into sizes of 1 "-2". It is then
weighed and fed into the heating tank. This is heated to 140 degree C - 150
degree C. In the molten state this is poured into the blending tank and
blended
for 10 minutes.
3. Remaining toluene and white spirit solvents are pumped into the
blending tank at this stage.
4. The rubber which was pre-weighed and dissolved by stirring with
50% of the toluene is then added at this stage. Blend for 20 minutes.
Reaction/bonding must occur.
5. Silica is then added at this stage.
6. Finally the methylated spirit is poured into the blending tank to
give a uniform consistency.
7. The product is then fed through the vibratory screen of sizes 25
mesh and 80 mesh for a finished product.
8. The blending tank is jacketed to allow a cooling solution to flow
through during the blending process. Temperature of finished product:
50° C
60° C.
Additional information, in the form of a data sheet, regarding
characteristics and usage of this exemplary underbody coating/sound deadener
product are set forth below:
*rB
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GENERIC TYPE . Rubberized Natural Asphalt
base
RECOMMENDED USES . Undercoating of all vehicles
GENERAL PROPERTIES : A blend of natural asphalt
and
fillers, etc. designed to
give superb
anti-corrosive and sound
deadening
properties. Both wet and
dry films
show no sagging.
CHEMICAL RESISTANCE . Resistant to splashes of
all petroleum
solvents, e.g., gasoline,
diesel fuel
etc. Do not wipe area. Just
allow
area to dry naturally. No
lifting of
film occurs.
TEMPERATURE . Can be stoved up to 150
C for 30
mins.
LIMITATIONS
SURFACE PREPARATION . Ensure area is dry, free
from dust
and grease.
PRIMING : Not necessary
THINNING & CLEAN-UP . Surecoat Thinner #AP2 Reducer
_ TOP COAT REQUIRED : Not necessary
OVERCOATING & : N.C. Lacquer; Synthetic
Resin, Non-
S and,
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UNDERCOATING . H. Dur Rapid Extra Filler, Red Zinc
Chromate Metal, Universal Metal,
Yellow Zinc Chromate Metal
APPLICATION : Remove rust, scale, oil and grease
from surface to be coated. Ensure
area is dry.
PERFORMANCE : Stowing - can be stowed or air dried
to a hard yet flexible film. Stowing
can be up to 150° C (or lower) for
30 minutes
HUMIDITY TEST . On bare steel for 14 weeks at 49° C
complete immersion in water. No
deterioration of panel. Before and
after immersion, the Carrie and
Erichsen tests were performed on the
panels. The Carrie test is related to
the adhesive properties of the
undercoating onto steel panel, whilst
the Erichsen test is related both to
the adhesion and elasticity of the
undercoating. This product passes
both tests.
SPECIFICATIONS
SOLIDS CONTENT : 80-82%
DRY FILM THICKNESS . 320 um (per coat)
*rB
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COVERAGE . 43m2 (163 sq. ft./L1S gal)
SHELF LIFE - . Indefinite, once properly closed
COLOR . Black
APPLICATION TEMPERATURE . Ambient
DRYING TIME . Touch dry 1-2 hours. Allow 24
hours before painting coating.
VISCOSITY . 370-380 (penetration, grease cone
25° C)
FLASH POINT . 37° C
WEIGHT PER US GALLON : 4.54 kg (10 lb.)
CORROSION TEST . Salt spray. ASTM B117. No
corrosion.
WATER TANK PAINT EXAMPLE
The following is an example of a water tank paint product made in
accordance with one embodiment of the instant invention. A variety of improved
water tank paint products can be made using the following elements in the
approximate ranges (percent by weight) set forth below:
TLA 1% to 85%
Polymers/Co-Polymers 1 % to 60%
Carrier 1 % to 60%
Clay 1 % to 60%
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In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the water tank paint product may be as follows:
Percentage by weight of Raw Materials:
Trinidad Natural Asphalt 47.00
$ White Spirit 21.67
Claytone 40 1.72
Methylated Spirit 0.43
Toluene 14.59
Rubber 0.43
Silica Flour 14.16
A preferred process for making this product is as follows:
1. Claytone 40 is stirred with 40% of the white spirit to form a slurry
and poured into blending tank.
2. Asphalt is crushed in a pulveriser into sizes of 1 "-2". It is then
weighed and fed into the heating tank. This is heated to 140 degree C - 150
degree C. In the molten state this is poured into the blending tank and
blended
for 10 minutes.
3. Remaining toluene and white spirit solvents are pumped into the
blending tank at this stage.
_ 4. The rubber which was pre-weighed and dissolved by stirring with
50% of the toluene is then added at this stage. Blend for 20 minutes, reaction
bonding must occur.
5. Silica is then added at this stage.
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6. Finally the methylated spirit is poured into the blending tank to
give a uniform consistency.
7. The product is then fed through the vibratory screen of sizes 25
mesh and 80 mesh for a finished product.
8. The blending tank is jacketed to allow a cooling solution to flow
through during the blending process. Temperature of finished product:
50° C-60°
C.
Additional, information, in the form of a data sheet, regarding
characteristics and usage of this exemplary water tank paint product are set
forth
below. This product provides a non-toxic coating for the internal surface of
drinking water tanks. It is a natural asphalt-based rubberized product in an
organic solvent.
COMPONENT . Single pack
SURFACE PREPARATION . Make sure that surface is dry and
free of grease and dust.
APPLICATION . Brush, spray or roll-on
COLOR : Black
SOLIDS CONTENT . 65-70%
SPECIFIC GRAVITY . 1.03-1.10
FLASH POINT . 37° C
DRY FILM THICKNESS : 40-50 microns
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SHELF LIFE . Unlimited. Replace lid when not in
use.
DRYING TIIvIE : Touch dry 1 hour. Overcoat 8-12
hours
COLOR . Black
COVERAGE . 8 sq. meter per liter
RECOMMENDED USES . Any potable water system
THINNING & CLEAN-UP . Surecoat #AP2 Reducer
CHASSIS BLACK PRODUCT EXAMPLE
The following is an example of a chassis black product made in
accordance with one embodiment of the instant invention. A variety of improved
water chassis black products can be made using the following elements in the
approximate ranges (percent by weight) set forth below:
TLA 1 % to 80%
Polymers/Co-Polymers 1 % to 80%
Carrier 1 % to 50%
Clay 1 % to 40%
In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the chassis black paint product may be as
follows:
Percentage by weight of Raw Materials:
TLA 48.00
White Spirit 21.67
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Claytone 40 1.72
Methylated Spirit 0.43
Toluene 14.59
Rubber 0.43
Silica Flour 13.16
A preferred process for making this product is as follows:
1. Claytone 40 is stirred with 40% of the white spirit to form a slurry
and poured into blending tank.
2. Asphalt is crushed in a pulverises into sizes of 1 "-2". It is then
weighed and fed into the heating tank. This is heated to 140 degree C - 150
degree C. In the molten state this is poured into the blending tank and
blended
for 10 minutes.
3. Remaining toluene and white spirit solvents are pumped into the
blending tank at this stage.
4. The rubber which was pre-weighed and dissolved by stirring with
50% of the toluene is then added at this stage. Blend for 20 minutes, reaction
bonding must occur.
5. Silica is then added at this stage.
- 6. Finally the methylated spirit is poured into the blending tank to
give a uniform consistency.
7. The product is then fed through the vibratory screen of sizes 25
mesh and 80 mesh for a finished product.
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8. The blending tank is jacketed to allow a cooling solution to flow
through during the blending process. Temperature of finished product:
50° C-60°
C -
Additional information, in the form of a data sheet, regarding
characteristics and usage of this exemplary chassis black product are set
forth
below. The product provides a non-emulsion natural asphalt-based, rubberized
coating designed to give a low sheen finish. It contains very fine fillers so
as to
obtain maximum protection. The coating dries to a hard finish.
SURFACE PREPARATION : For previously painted surfaces
remove all loose, flaking and peeling
paint with the use of a metal scraper
or wire brush. Also remove all
grease oil and other debris from
surface. Wipe area dry and apply
coating. Prime with Surecoat's Zinc
Chromate Black if necessary.
COMPONENT . Single pack
APPLICATION . Brush, spray or roll-on
COLOR . Black
SHELF LIFE : Indefinite, once properly closed
DRYING TIME . Touch dry 10-15 mins. Recoat - 60
mins.
FLASH POINT . 37° C
COVERAGE . 7.10 sq meter per liter
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DRY FILM THICKNESS : 90-95 microns
SOLIDS CONTENT : 66-68%
SPECIFIC GRAVITY . 1.12-1.14
RECOMMENDED USES . For chassis, under carriages, trailers,
engine body and running boards
THINNING & CLEAN UP . Surecoat #AP2 Reducer
ZINC CHROMATE PRIMER BLACK PRODUCT EXAMPLE
The following is an example of a zinc chromate primer black product
made in accordance with one embodiment of the instant invention. A variety of
improved zinc chromate primer black products can be made using the following
elements in the approximate ranges (percent by weight) set forth below:
TLA 1 % to 90%
Polymers/Co-Polymers 1 % to 60%
Carrier 1 % to 60%
Clay 1% to 60%
Pigment 1 % to 80%
In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the zinc chromate primer black product may be as
follows:
Percentage by weight of Raw Materials:
Trinidad Natural Asphalt 43.64
White Spirit 26.31
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Claytone 40 1.54
Methylated Spirit 0.44
Toluene 12.28
Rubber 0.44
Silica Flour 13.16
Zinc Chromate Pigment 2.19
A preferred process for making this product is as follows:
1. Claytone 40 is stirred with 40% of the white spirit to form a slurry
and poured into blending tank.
2. Asphalt is crushed in a pulverises into sizes of 1 "-2". It is then
weighed and fed into the heating tank. This is heated to 140 degree C - 150
degree C. In the molten state this is poured into the blending tank and blend
for
10 minutes.
3. Remaining toluene and white spirit solvents are pumped into the
blending tank at this stage.
4. The rubber which was pre-weighed and dissolved by stirring with
50% of the toluene is then added at this stage. Blend for 20 minutes, reaction
bonding must occur.
5. Silica flour and zinc chromate pigment are then added at this stage.
6. Finally the methylated spirit is poured into the blending tank to
give a uniform consistency.
7. The product is then fed through the vibratory screen of sizes 25
mesh and 80 mesh for a finished product.
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8. The blending tank is jacketed to allow a cooling solution to flow
through during the blending process. Temperature of finished product:
50° C-60°
C
Additional information, in the form of a data sheet, regarding
characteristics and usage of this exemplary zinc chromate primer black product
are set forth below.
This product provides a rubberized natural asphalt coating to which has
been added a rust inhibitor.
PRODUCT : 1 ) Excellent water resistance
CHARACTERISTICS 2) Fast drying
3) Excellent anti-corrosive
properties
COMPONENT : One pack
SURFACE PREPARATION . For normal conditions, hand or
power tool cleaning is necessary.
Surfaces should be free of grease, oil
and debris. For severe conditions of
exposure, sand blasting to S.S.P.C.6
is recommended.
COVERAGE . 6 sq. meter/per liter
DRY FILM THICKNESS : 80-85 microns
SOLIDS CONTENT : 64-68%
SPECIFIC GRAVITY : 1.13
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DRYING TIME . 30-45 mins. to touch. Recoat 18-24
hours
FLASH POINT . 37° C
APPLICATION . Brush, spray or roll-on
COLOR . Black
SHELF LIFE . Indefinite once properly closed
RECOMMENDED USES . On all metal surfaces, where priming
is necessary.
THINNING & CLEAN-UP . Surecoat #AP4 Reducer
ZINC CHROMATE PRIMER GREY PRODUCT EXAMPLE
The following is an example of a zinc chromate primer grey product made
in accordance with one embodiment of the instant invention. A variety of
improved zinc chromate primer grey products can be made using the following
elements in the approximate ranges (percent by weight) set forth below:
TLA 1% to 85%
Polymers/Co-Polymers 1% to 60%
Carrier 1 % to 60%
Clay 1 % to 60%
Pigment 1 % to 80%
In accordance with a more particular embodiment, the raw materials and
percent by weight thereof in the zinc chromate primer grey product may be as
follows:
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Percentage by weight of Raw Materials:
Trinidad Natural Asphalt 32.41
White Spirit 37.50
Claytone 40 2.08
Methylated Spirit 0.46
Toluene 1 S.OS
Rubber 0.46
Zinc Chromate Pigment 1.62
Titanium Dioxide Pigment 10.42
A preferred process for making this product is as follows:
1. Claytone 40 is stirred with 40% of the white spirit to form a slurry
and poured into blending tank.
2. Asphalt is crushed in a pulveriser into sizes of 1 "-2". It is then
weighed and fed into the heating tank. This is heated to 140 degrees C - 150
degrees C. In the molten state this is poured into the blending tank and
blended
for 10 minutes.
3. Remaining toluene and white spirit solvents are pumped into the
blending tank at this stage.
4. The rubber which was pre-weighed and dissolved by stirring with
50% of the toluene is then added at this stage. Blend for 20 minutes, reaction
bonding must occur.
5. Zinc chromate pigment and titanium dioxide pigment are then
added at this stage.
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6. Finally the methylated spirit is poured into the blending tank to
give a uniform consistency.
7. The product is then fed through the vibratory screen of sizes 25
mesh and 80 mesh for a finished product.
8. The blending tank is jacketed to allow a cooling solution to flow
through during the blending process. Temperature of finished product:
50° C-
60° C
Additional information, in the form of a data sheet, regarding
characteristics and usage of this exemplary zinc chromate primer grey product
are
set forth below.
This product provides a two-in-one rubberized natural asphalt coating.
It has all the properties of the zinc chromate primer black product described
above, but is pigmented to a grey finish.
COMPONENT . One pack
SURFACE PREPARATION . Surfaces should be free from grease,
oil or rust. Remove rust using a
wire brush or a power tool. See
zinc chromate primer black product
above.
COVERAGE . 6 sq. meter/liter
DRY FILM THICKNESS . 80-100 microns
SOLIDS CONTENT . 60-70%
SPECIFIC GRAVITY . 1.14
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DRYING TIME . 30-45 minutes
FLASH POINT . 37° C
APPLICATION . Brush, spray or roll-on
COLOR . Bone grey
AREAS OF USE . On metal surfaces
THINNING & CLEAN-UP : Surecoat #AP4 Reducer
RECOMMENDED USES . On all metal surfaces, where priming
is necessary. No overcoat required.
ROAD MARKING PRODUCT EXAMPLE
The following is an example of a road marking product made in
accordance with one embodiment of the instant invention. A variety of improved
road marking products can be made using the following elements in the
approximate ranges (percent by weight) set forth below:
TLA 1% to 80%
Polymers/Co-polymers 1 % to 95%
Carriers 1 % to 80%
Clays 1 % to 80%
Different polymers/co-polymers are used such that different Tg's (i.e. glass
transition temperatures) are obtained. This enables the road-marking paint to
remain flexible at extremely low temperatures. The complete TLA can be used,
so that no part of the TLA has to be removed. The process involves the
reaction
of TLA with a Polymer/Elastomer mixture, a reaction between TLA and silica,
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and a reaction between TLA and clays. If desired, any color can be created
through the addition of Pigments. The resulting Coating can be epoxidised or
non-epoxidised.
All of the coating products described above are environmentally friendly
and can be advantageously used in place of many prior art coatings. The
coatings
can be used in, for example, the marine environment, potable water systems,
sewer systems, heavy industry, construction industry, environmentally
oppressive
conditions, and many other applications.
The coatings made in accordance with the instant invention are, among
other things: resistant to petroleum distillates; aromatic solvents; salt
water
immersion; acids; alkalis; sour crudes and lubricating oils; and sea blast.
The
coatings are also unaffected by, for example, fresh water; deionized/distilled
water
systems; bromides; chlorides; and sulphates;
In addition, the coatings have enhanced durability, flexibility; resistance to
abrasion; resistance to an applied force; resistance to aromatic solvents; and
aesthetic properties. The coatings may also be used in low temperature
environments without degradation.
It is noted that, in accordance with the instant invention, in any of the
exemplary processes described above, a Banbury mixer or high shear internal
mixer can be used to ensure that reaction bonding occurs between, for example,
the TLA, raw material and clay.
While the preferred forms and embodiments of the invention have been
illustrated and described, it will be apparent to those of ordinary skill in
the art
that various changes and modifications may be made without deviating from the
inventive concepts and true spirit of the invention as set forth above, and it
is
intended by the appended claims to cover all such changes and modification
which come within the full scope and true spirit of the invention.
