Barrier coatings

Abstract

The invention relates to a method of preventing a material from adhering to a surface. In a preferred embodiment, the material comprises weld spatter and the surface is located near a welding operation. The method comprises coating the surface with a slurry comprising a mineral material in water. The slurry contains from 10% to 70% solids by weight and not more than 5% by weight of a material that decomposes when heated to 1000° F. for one minute. The slurry is allowed to dry to form a barrier coating before the material contacts the surface.

1 - 21 . (canceled)  
     
     
         22 . A manufactured slurry for forming a barrier coating to prevent a material from adhering to a surface, the slurry comprising a mineral material in water, the slurry containing from about 10% to about 70% solids by weight and not more than 1% by weight of a material that fumes or smokes when heated to 1000° F. for one minute; 
 the slurry when dried forming the barrier coating that binds to the surface such that at least about 50 finger double rubs are required to reach the surface when the dry barrier coating is 30 microns thick.    
     
     
         23 . A slurry according to  claim 22  wherein the barrier coating is a welding machine maintenance coating to prevent weld spatter from adhering to the surface.  
     
     
         24 . A slurry according to  claim 22  wherein the slurry includes a plurality of mineral materials.  
     
     
         25 . A slurry according to  claim 22  wherein the slurry contains substantially no material that fumes or smokes when heated to 1000° F. for one minute.  
     
     
         26 . A slurry according to  claim 22  wherein the slurry is sprayable.  
     
     
         27 . A slurry according to  claim 22  wherein the slurry has a rheology that prevents the slurry from sagging or running on a vertical surface when applied at a temperature of 72° F.  
     
     
         28 . A slurry according to  claim 22  wherein the slurry contains substantially no organic solvent.  
     
     
         29 . A manufactured slurry for forming a barrier coating to prevent a material from adhering to a surface, the slurry comprising a mineral material in water, the slurry containing from about 10% to about 70% solids by weight and not more than 1% by weight of a material that fumes or smokes when heated to 1000° F. for one minute; 
 the slurry when dried forming the barrier coating, and drying in a time not longer than about 15 minutes when the slurry is applied as a 250 micron thick wet film and with the temperature at 73° F., 59% humidity, and air moving over the film at 90 feet per minute.    
     
     
         30 . A slurry according to  claim 29  wherein the barrier coating is a welding machine maintenance coating to prevent weld spatter from adhering to the surface.  
     
     
         31 . A slurry according to  claim 29  wherein the slurry includes a plurality of mineral materials.  
     
     
         32 . A slurry according to  claim 29  wherein the slurry contains substantially no material that fumes or smokes when heated to 1000° F. for one minute.  
     
     
         33 . A slurry according to  claim 29  wherein the slurry is sprayable.  
     
     
         34 . A slurry according to  claim 29  wherein the slurry has a rheology that prevents the slurry from sagging or running on a vertical surface when applied at a temperature of 72° F.  
     
     
         35 . A manufactured slurry for forming a barrier coating to prevent a material from adhering to a surface, the slurry comprising water, a mineral material, and a rheology control agent selected from the group consisting of anti-sagging, anti-settling and anti-synersis agents, the slurry containing from about 10% to about 70% solids by weight and not more than 1% by weight of a material that fumes or smokes when heated to 1000° F. for one minute.  
     
     
         36 . A slurry according to  claim 35  wherein the slurry further includes a rust inhibitor.  
     
     
         37 . A slurry according to  claim 35  wherein the barrier coating is a welding machine maintenance coating to prevent weld spatter from adhering to the surface.  
     
     
         38 . A slurry according to  claim 35  wherein the slurry includes a plurality of mineral materials.  
     
     
         39 . A slurry according to  claim 35  wherein the slurry contains one or more mineral materials selected from the group consisting of aluminum tri-hydroxide, magnesium hydroxide, graphite, hexagonal boron nitride, and mixtures thereof.  
     
     
         40 . A slurry according to  claim 35  wherein the slurry contains one or more mineral materials selected from the group consisting of sodium magnesium aluminosilicate, diatomaceous earth, pumice, amorphous silica, and mixtures thereof.  
     
     
         41 . A slurry according to  claim 35  wherein the slurry contains one or more mineral materials selected from the group consisting of calcium carbonate, calcined clay, delaminated kaolin clay, kaolin clay, talc, and mixtures thereof.