Superabsorbent water-resistant coatings for fiber-reinforced articles

Abstract

A coating composition for forming a water-resistant coating on fiber-reinforced articles such as rods or cables. The composition comprises an aqueous solution of a superabsorbent water-soluble polymer, a viscosity modifying agent, and optionally a lubricant. The coating formed by applying the composition effectively prevents the treated surface from water-permeation damage by absorbing water that contacts the layer containing the superabsorbent component.

1 - 27 . (canceled)  
   
   
       28 . A superabsorbent coating for reinforcing fiber strands or rovings, the coating comprising: 
 a single layer of a substantially homogeneous and non-particulate mixture of a superabsorbent, water-swellable polymer, a non-particulate viscosity-modifying agent and a binder, said superabsorbent, water-swellable polymer demonstrating water absorption when said coating is wetted and demonstrating water desorption when said coating is dried without loss of said superabsorbent, water-swellable polymer from said coating;    said single layer coating exhibiting, when immersed in an aqueous environment, a swell capacity of up to about 400 times an initial dry weight of said superabsorbent, water-swellable polymer, and    said single layer coating further exhibiting, when applied to a reinforcing fiber strand or roving, a swell rate of from about 300 percent weight to about 2000 percent weight of a total weight of said superabsorbent, water-swellable polymer and said reinforcing fiber strand or roving within a first minute of being immersed in an aqueous environment.    
   
   
       29 . The superabsorbent coating of  claim 28 , wherein said superabsorbent, water-swellable polymer includes a superabsorbent polacrylate polymer.  
   
   
       30 . The superabsorbent coating of  claim 28 , wherein said single layer coating has a swell rate of from about 50 grams of deionized water per gram of said single layer coating when dry to about 340 grams of deionized water per gram of said single layer coating when dry within said first minute of being wetted.  
   
   
       31 . The superabsorbent coating of  claim 28 , wherein said single layer coating has a swell rate of from about 33 grams of salt water per gram of said coating when dry to about 66 grams of salt water per gram of said coating when dry within a first minute of being wetted.  
   
   
       32 . The superabsorbent coating of  claim 28 , wherein said single layer coating has a swell rate of about 126 grams of deionized water per gram of said coating when dry and about 50 grams of salt water per gram of said single layer coating when dry within a first minute of being wetted.  
   
   
       33 . The superabsorbent coating of  claim 28 , wherein said non-particulate viscosity-modifying agent is selected from the group consisting of alkyl celluloses, acrylamide polymers and mixtures thereof.  
   
   
       34 . The superabsorbent coating of  claim 28 , wherein said binder includes a film-forming binder selected from the group consisting of polyesters, polyurethanes, epoxies, latexes, and mixtures thereof.  
   
   
       35 . The superabsorbent coating of  claim 28 , wherein said single layer coating further includes at least one of a lubricant and a wetting agent.  
   
   
       36 . The superabsorbent coating of  claim 28 , wherein said reinforcing fiber strand or roving includes fibers selected from the group consisting of glass fibers, polymer fibers, carbon fibers, natural fibers, and blends thereof.  
   
   
       37 . The superabsorbent coating of  claim 36 , wherein said polymer fibers include fibers selected from the group consisting of aramid fibers, nylon fibers, Kevlar fibers, polyester fibers, polyethylene fibers, polypropylenes fibers, and blends thereof.  
   
   
       38 . A superabsorbent coating for a composite article including at least one reinforcing fiber material, the coating comprising: 
 a single layer of a substantially homogeneous and non-particulate mixture of a superabsorbent, water-swellable polymer, a non-particulate viscosity-modifying agent and a binder, said superabsorbent, water-swellable polymer demonstrating water absorption when said coating is wetted and demonstrating water desorption when said coating is dried without loss of said superabsorbent, water-swellable polymer from said coating;    said single layer coating exhibiting, when immersed in an aqueous environment, a swell capacity of up to about 400 times an initial dry weight of said superabsorbent, water-swellable polymer: and    
     said single layer coating further exhibiting, when applied to said composite article, a swell rate of from about 300 percent weight to about 2000 percent weight of a total weight of said superabsorbent, water-swellable polymer and said reinforcing fiber material within a first minute of being immersed in an aqueous environment.  
   
   
       39 . The superabsorbent coating of  claim 38 , wherein said composite article includes a rod, cable or article formed from a pultrusion operation.