Corrosion inhibitor

Abstract

The present invention relates to a corrosion inhibitor and a corrosion inhibiting coating provided for coating a metal, particularly but not exclusively steel. The inhibitors pigment will also protect aluminium and magnesium alloys. The corrosion inhibitor particularly protects a sacrificial coating such as zinc or zinc alloy on galvanised steel, which in turn therefore provides improved corrosion resistance to the underlying steel. The present invention comprises an organic cation in a cation exchange resin.

1 . A corrosion inhibitor comprising:
 an organic cation in a cation exchange resin.   
     
     
         2 . A corrosion inhibitor according to  claim 1 , wherein the organic cation in the cation exchange resin is particulate. 
     
     
         3 . A corrosion inhibitor as recited in  claim 1 , wherein the organic cation is an azole or an oxime. 
     
     
         4 . A corrosion inhibitor as recited in  claim 1 , wherein the organic cation is benzotriazole or a derivative thereof. 
     
     
         5 . A corrosion inhibitor as recited in  claim 1 , wherein the cation exchange resin is an organic cation exchange resin matrix. 
     
     
         6 . A corrosion inhibitor as recited in  claim 5 , wherein the cation exchange resin is a styrene and/or divinylbenzene copolymer with a negatively charged group. 
     
     
         7 . A corrosion inhibitor as recited in  claim 6 , wherein the styrene and divinylbenzene copolymer has a negatively charged sulphonated functional group. 
     
     
         8 . A corrosion inhibitor as recited in  claim 2 , wherein particulate size of the corrosion inhibitor is less than 5 microns. 
     
     
         9 . A corrosion inhibitor as recited in  claim 1 , wherein a ratio of organic cation to cation exchange resin is approximately 10% by weight of organic cation to cation exchange resin. 
     
     
         10 . An additive for addition to a coating for imparting corrosion resistance upon a substrate comprising:
 a first corrosion inhibitor comprising an organic cation in a cation exchange resin; and   a second corrosion inhibitor comprising inorganic cation modified silica.   
     
     
         11 . An additive as recited in  claim 10 , wherein the inorganic cation modified silica comprises calcium cation modified silica. 
     
     
         12 . An additive as recited in  claim 10 , wherein the inorganic cation modified silica is particulate. 
     
     
         13 . An additive as recited in  claim 10 , wherein the first corrosion inhibitor and the second corrosion inhibitor comprise a particulate mixture. 
     
     
         14 . An additive for addition to a coating for imparting corrosion resistance upon a substrate comprising a first corrosion inhibitor comprising an organic cation in a cation exchange resin,
 a second corrosion inhibitor comprising an inorganic cation in a cation exchange resin.   
     
     
         15 . A coating for a metal substrate comprising:
 a corrosion inhibitor or additive comprising an organic cation in a cation exchange resin provided in a polymer binder.   
     
     
         16 . A coating according to  claim 15 , wherein the polymer binder is selected from one or more of an acrylic, polyurethane or polyvinyl butyral. 
     
     
         17 . A coating as recited in  claim 15 , in a form of a paint. 
     
     
         18 . A metal substrate coated with a coating comprising a corrosion inhibitor or additive comprising an organic cation in a cation exchange resin provided in a polymer binder. 
     
     
         19 . A metal substrate according to  claim 18 , wherein the metal substrate is steel, or an alloy based on steel. 
     
     
         20 . A method of manufacturing a corrosion inhibitor comprising: combining organic cations with a cation exchange resin. 
     
     
         21 . A method as recited in  claim 20 , further comprising:
 providing the organic cations in solution; and   combining the cation exchange resin with the solution to form beads.   
     
     
         22 . A method comprising:
 providing a corrosion inhibitor or additive comprising an organic cation in a cation exchange resin provided in a polymer binder;   wherein the organic cations are produced by dissolving an organic compound into solution, the organic compound being capable of dissociating into at least two ions, one of the ions being the organic cation, wherein the solution has a pH of less than 3.   
     
     
         23 . A method of manufacturing a corrosion inhibitor, comprising:
 providing an organic compound in solution and combining with a cation exchange resin having a negatively charged functional group for dissociating the organic compound to organic cations and anions, wherein the organic cations and cation exchange resin together form the corrosion inhibitor.   
     
     
         24 . A method as recited in  claim 23  wherein, the corrosion inhibitor is formed into beads, and the beads are filtered from solution. 
     
     
         25 . A method as recited in  claim 24 , comprising drying the beads. 
     
     
         26 . A method as recited in  claim 25 , further comprising breaking up the beads into smaller particles. 
     
     
         27 . A method as recited in  claim 20 , wherein the organic cations are an azole and preferably comprise benzotriazole. 
     
     
         28 . A method as recited in  claim 20 , wherein the cation exchange resin is an organic cation exchange resin. 
     
     
         29 . A method as recited in  claim 28 , further comprising combining a second corrosion inhibitor comprising an inorganic cation in a cation exchange resin. 
     
     
         30 . A method as recited in  claim 26 , further comprising mixing the smaller particles with a second corrosion inhibitor comprising particulate inorganic cation modified silica. 
     
     
         31 . A method of manufacturing a coating for a metal substrate comprising:
 combining a corrosion inhibitor comprising an organic cation exchange resin with a polymer binder.