Non-metallic -tank anti-leak, self-sealing coating

Abstract

A differential-thickness, self-sealing, anti-leak, all-over coating for the outside surface of a fuel container formed of HDPE plastic material and characterized with differentiated high and low puncture-threat regions. The coating includes, for the high-threat regions, a plural-layer portion possessing (a) an inner, high-elastomeric layer bonded substantially directly to the overlying portion of the container wall's outer surface, (b) an intermediate, high-elastomeric layer including a population of embedded, liquid-fuel imbiber beads formed over the inner layer, and (c) an outer, high-elastomeric layer formed over the intermediate layer, and for the low-threat regions, a single-layer portion bonded substantially directly to the overlying portion of the container wall's outer surface, and having a single, high-elastomeric layer which joins in a bridging manner, and in a differential-thickness transition region, to each of the plural-layer portion's layers to form collaboratively therewith a fully enveloping, elastomeric, shrink-wrap jacket around the container.

1 . (canceled) 
     
     
         2 . The coating of  claim 4 , wherein the outer surface of the container wall is a non-shiny, textured, roughened surface, and wherein the coating further includes a film of mechanical-bond-enhancing primer disposed between this roughened surface and the plural-layer and single-layer portions in said coating. 
     
     
         3 . (canceled) 
     
     
         4 . A self-sealing, anti-liquid-leak, all-over layer-based coating for a liquid petroleum fuel container having an outer wall which defines lateral, bottom and top sides of the container each with an outer surface formed of HDPE plastic material, said layer-based coating having, for different, respective ones of the mentioned sides in the container, different overall thicknesses, and respectively associated, different numbers of layer, said coating comprising
 for each of the lateral and bottom sides, a first, common-thickness coating portion possessing three layers including (a) an inner, high-elastomeric material layer applied substantially directly to the side and mechanically bonded thereto, (b) an intermediate layer formed over said inner layer including a combination of substantially the same high-elastomeric material employed in said inner layer and additionally a population of embedded, liquid-fuel imbiber beads, and (c) an outer layer applied over said intermediate layer and formed of substantially the same high-elastomeric material which is employed in said inner layer, and   for the top side, a single, second-coating-portion, top-side layer formed of substantially the same high-elastomeric material employed in said inner and outer layers in said first coating portion, joining with each of said inner, intermediate and outer layers in said first coating portion, and together with said first coating portion's said outer layer forming an elastomeric, shrink-wrap continuum fully and effectively enveloping the container.   
     
     
         5 . A self-sealing, anti-liquid-leak, all-over layer-based coating for a liquid petroleum fuel container having an outer wall which defines lateral, bottom and top sides of the container each with an outer surface formed of HDPE plastic material, said layer-based coating having, for different, respective ones of the mentioned sides in the container, different overall thicknesses, and respectively associated, different numbers of layer, said coating comprising
 for each of the lateral and bottom sides, a first, common-thickness coating portion possessing three layers including (a) an inner, high-elastomeric material layer with a thickness lying selectively in the range of about 0.200-0.280-inches applied substantially directly to the side and mechanically bonded thereto, (b) an intermediate layer formed over said inner layer, having a thickness lying selectively in the range of about 0.125-0.160-inches and including a combination of substantially the same high-elastomeric material employed in said inner layer and additionally a population of embedded, liquid-fuel imbiber beads, and (c) an outer layer having a thickness lying selectively in the range of about 0.060-0.175-inches applied over said intermediate layer and formed of substantially the same high-elastomeric material which is employed in said inner layer, whereby the collective thickness of the selected-thickness inner, intermediate and outer layers in said first coating portion is about 0.5-inches, and   for the top side, a single, second-coating-portion, top-side layer having a thickness of about 0.150-inches formed of substantially the same high-elastomeric material employed in said inner and outer layers in said first coating portion, joining with each of said inner, intermediate and outer layers in said first coating portion, and together with said first coating portion's outer layer forming an elastomeric, shrink-wrap continuum fully and effectively enveloping the container.   
     
     
         6 . The coating of  claim 5 , wherein the outer surface of the container wall is a non-shiny, textured, roughened surface, and wherein the coating further includes a film of appropriate mechanical-bond-enhancing primer disposed between this roughened surface and the plural-layer and single-layer portions layers in said coating.