US20100051199A1 - Process for providing an extended tubular article with a corrosion protection coating system having self-repairing properties - Google Patents
Process for providing an extended tubular article with a corrosion protection coating system having self-repairing properties Download PDFInfo
- Publication number
- US20100051199A1 US20100051199A1 US12/513,984 US51398407A US2010051199A1 US 20100051199 A1 US20100051199 A1 US 20100051199A1 US 51398407 A US51398407 A US 51398407A US 2010051199 A1 US2010051199 A1 US 2010051199A1
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- US
- United States
- Prior art keywords
- process according
- branched
- optionally substituted
- linear
- polymer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 38
- 238000005260 corrosion Methods 0.000 title claims abstract description 36
- 230000007797 corrosion Effects 0.000 title claims abstract description 36
- 238000000576 coating method Methods 0.000 title description 27
- 239000011248 coating agent Substances 0.000 title description 21
- 230000004224 protection Effects 0.000 title description 7
- 239000000203 mixture Substances 0.000 claims abstract description 97
- 230000001070 adhesive effect Effects 0.000 claims abstract description 57
- 239000000853 adhesive Substances 0.000 claims abstract description 56
- 239000000463 material Substances 0.000 claims description 44
- 229920000098 polyolefin Polymers 0.000 claims description 41
- 229920002367 Polyisobutene Polymers 0.000 claims description 35
- 229920000642 polymer Polymers 0.000 claims description 26
- VQTUBCCKSQIDNK-UHFFFAOYSA-N Isobutene Chemical compound CC(C)=C VQTUBCCKSQIDNK-UHFFFAOYSA-N 0.000 claims description 22
- QQONPFPTGQHPMA-UHFFFAOYSA-N Propene Chemical compound CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 22
- 239000000945 filler Substances 0.000 claims description 21
- 230000009477 glass transition Effects 0.000 claims description 15
- 229920001577 copolymer Polymers 0.000 claims description 14
- 229910000831 Steel Inorganic materials 0.000 claims description 12
- 239000010959 steel Substances 0.000 claims description 12
- 229920005989 resin Polymers 0.000 claims description 10
- 239000011347 resin Substances 0.000 claims description 10
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 claims description 9
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 claims description 9
- WWUVJRULCWHUSA-UHFFFAOYSA-N 2-methyl-1-pentene Chemical compound CCCC(C)=C WWUVJRULCWHUSA-UHFFFAOYSA-N 0.000 claims description 6
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 6
- 239000004567 concrete Substances 0.000 claims description 6
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 claims description 5
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 claims description 4
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 claims description 4
- IAQRGUVFOMOMEM-UHFFFAOYSA-N but-2-ene Chemical compound CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 claims description 4
- 229920001519 homopolymer Polymers 0.000 claims description 4
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 claims description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 claims 2
- XNMQEEKYCVKGBD-UHFFFAOYSA-N dimethylacetylene Natural products CC#CC XNMQEEKYCVKGBD-UHFFFAOYSA-N 0.000 claims 1
- 125000005843 halogen group Chemical group 0.000 claims 1
- 150000003440 styrenes Chemical class 0.000 claims 1
- 239000010410 layer Substances 0.000 description 48
- -1 cyclic diolefins Chemical class 0.000 description 26
- 239000004743 Polypropylene Substances 0.000 description 19
- 239000003963 antioxidant agent Substances 0.000 description 19
- 235000006708 antioxidants Nutrition 0.000 description 19
- 229920001155 polypropylene Polymers 0.000 description 19
- 230000003078 antioxidant effect Effects 0.000 description 17
- 229920001971 elastomer Polymers 0.000 description 12
- 239000005060 rubber Substances 0.000 description 12
- 229920005549 butyl rubber Polymers 0.000 description 10
- 230000001681 protective effect Effects 0.000 description 8
- 239000013521 mastic Substances 0.000 description 7
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 7
- 239000011253 protective coating Substances 0.000 description 7
- 238000003466 welding Methods 0.000 description 7
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 5
- 239000012790 adhesive layer Substances 0.000 description 5
- 239000003208 petroleum Substances 0.000 description 5
- 229920001083 polybutene Polymers 0.000 description 5
- 239000004593 Epoxy Substances 0.000 description 4
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 4
- 239000002390 adhesive tape Substances 0.000 description 4
- 150000001336 alkenes Chemical class 0.000 description 4
- 239000003054 catalyst Substances 0.000 description 4
- 150000001993 dienes Chemical class 0.000 description 4
- 229920006334 epoxy coating Polymers 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000004831 Hot glue Substances 0.000 description 3
- 239000007767 bonding agent Substances 0.000 description 3
- 239000011243 crosslinked material Substances 0.000 description 3
- 229930195733 hydrocarbon Natural products 0.000 description 3
- 150000002430 hydrocarbons Chemical class 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 238000005488 sandblasting Methods 0.000 description 3
- 239000000565 sealant Substances 0.000 description 3
- 230000007704 transition Effects 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 2
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 description 2
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 2
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 2
- 238000009835 boiling Methods 0.000 description 2
- WTEOIRVLGSZEPR-UHFFFAOYSA-N boron trifluoride Chemical compound FB(F)F WTEOIRVLGSZEPR-UHFFFAOYSA-N 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical compound [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- ZSWFCLXCOIISFI-UHFFFAOYSA-N cyclopentadiene Chemical compound C1C=CC=C1 ZSWFCLXCOIISFI-UHFFFAOYSA-N 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 229910021485 fumed silica Inorganic materials 0.000 description 2
- 229910010272 inorganic material Inorganic materials 0.000 description 2
- 239000011147 inorganic material Substances 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000002203 pretreatment Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 235000012239 silicon dioxide Nutrition 0.000 description 2
- 229920001059 synthetic polymer Polymers 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 239000004711 α-olefin Substances 0.000 description 2
- 229910002012 Aerosil® Inorganic materials 0.000 description 1
- 229910015900 BF3 Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 238000005727 Friedel-Crafts reaction Methods 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 239000013032 Hydrocarbon resin Substances 0.000 description 1
- NHTMVDHEPJAVLT-UHFFFAOYSA-N Isooctane Chemical compound CC(C)CC(C)(C)C NHTMVDHEPJAVLT-UHFFFAOYSA-N 0.000 description 1
- 229920002633 Kraton (polymer) Polymers 0.000 description 1
- 239000002841 Lewis acid Substances 0.000 description 1
- 229920005987 OPPANOL® Polymers 0.000 description 1
- 229920002398 Oppanol® B Polymers 0.000 description 1
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 1
- COXUNHIKBNZLLM-UHFFFAOYSA-H [B+3].[B+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O Chemical compound [B+3].[B+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O COXUNHIKBNZLLM-UHFFFAOYSA-H 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 229920006271 aliphatic hydrocarbon resin Polymers 0.000 description 1
- 229920006272 aromatic hydrocarbon resin Polymers 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 238000010960 commercial process Methods 0.000 description 1
- 230000021615 conjugation Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 229920006037 cross link polymer Polymers 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 230000003413 degradative effect Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 239000000539 dimer Substances 0.000 description 1
- JVSWJIKNEAIKJW-UHFFFAOYSA-N dimethyl-hexane Natural products CCCCCC(C)C JVSWJIKNEAIKJW-UHFFFAOYSA-N 0.000 description 1
- 238000004821 distillation Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000005194 fractionation Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229920005555 halobutyl Polymers 0.000 description 1
- 230000009931 harmful effect Effects 0.000 description 1
- 231100001261 hazardous Toxicity 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 229920006270 hydrocarbon resin Polymers 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 150000002596 lactones Chemical class 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 150000007517 lewis acids Chemical class 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- NFWSQSCIDYBUOU-UHFFFAOYSA-N methylcyclopentadiene Chemical compound CC1=CC=CC1 NFWSQSCIDYBUOU-UHFFFAOYSA-N 0.000 description 1
- 150000002790 naphthalenes Chemical class 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 150000003097 polyterpenes Chemical class 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000012763 reinforcing filler Substances 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000010454 slate Substances 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 150000003505 terpenes Chemical class 0.000 description 1
- 235000007586 terpenes Nutrition 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- 238000004227 thermal cracking Methods 0.000 description 1
- 150000007970 thio esters Chemical class 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
- F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
- F16L58/04—Coatings characterised by the materials used
- F16L58/10—Coatings characterised by the materials used by rubber or plastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B1/00—Layered products having a general shape other than plane
- B32B1/08—Tubular products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
- C09D123/02—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D123/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
- C09D123/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
- C09D123/02—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D123/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
- C09D123/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
- C09D123/22—Copolymers of isobutene; Butyl rubber ; Homo- or copolymers of other iso-olefines
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
- C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
- C09J123/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
- C09J123/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
- C09J123/22—Copolymers of isobutene; Butyl rubber ; Homo- or copolymers of other iso-olefines
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2423/00—Presence of polyolefin
Definitions
- the present invention relates to a process for providing a pipe, pipeline or a part thereof with a coating system having self-repairing properties to protect the pipe, pipeline or part thereof against corrosion and other harmful and degradative effects, including environmental forces that impact the lifetime and operation of the pipe, pipeline or part thereof.
- Common corrosion protecting systems comprise coating systems, optionally comprising various layers of materials, shrink sleeves, and tapes, optionally provided with adhesive layers, and combinations of such systems.
- the rubber-based adhesive layer comprises a rubber mix and a tackifying resin.
- the rubber mix comprises crosslinked halogenated rubber, non-crosslinked rubber and a styrenic blockpolymer or terpolymer, e.g. a Kraton® polymer.
- the non-crosslinked rubber is preferably butyl rubber, preferably a mixture of virgin butyl rubber and recycled butyl rubber (butyl rubber is a copolymers of about 98 wt. % isobutene and 2 wt. % isoprene).
- the tackifying resin is used to provide the desired adhesiveness to the rubber mix and may be selected from a very large group of materials, e.g. rosins, modified rosins, rosin esters, polymerised petroleum hydrocarbons, polymerised terpenes and various resins. Examples 1 and 2 disclose formulations comprising different tackifiers, e.g.
- Endex® 155 an aromatic hydrocarbon resin available from Eastman Chemical Company, Indopol® H-100 (an isobutene/1-butene copolymer having a number average molecular weight of about 910, formally available from British Petroleum Chemicals, but currently available from e.g. Amoco Chemical Company and Innovene), Escorez® 1102 (an aliphatic hydrocarbon resin having an average molecular weight of about 1300, available from ExxonMobil), and Piccopale® 100 (a polyterpene resin).
- Escorez® 1102 is made by polymerising petroleum fractions having a boiling point from about 15° C. to about 410° C. at atmospheric pressure which are formed by the thermal cracking of petroleum feedstock.
- the fractions may be polymerised thermally or in the presence of a catalyst, for example a Friedel-Crafts catalyst such as AlCl 3 .
- a catalyst for example a Friedel-Crafts catalyst such as AlCl 3 .
- the petroleum feedstock e.g. light naphtha, heavy naphtha, kerosene, gas oil, vacuum gas oil and comprising C 5 olefins and diolefins, C 6 olefins and diolefins or a mixture of C 5 and C 6 olefines and diolefins
- the products from this cracking process usually have a boiling point of ⁇ 15° C. to 280° C.
- the product is subjected to fractionation to remove C 2 to C 4 light ends, thermal soaking and distillation to remove hydrocarbons such as cyclic diolefins including cyclopentadiene and methyl cyclopentadiene as dimers (cf. U.S. Pat. No. 4,690,958). Consequently, Escorez® 1102 and 1315 (see below) are not isobutene based polymers.
- the high shear tape according to U.S. Pat. No. 5,817,413 and U.S. Pat. No.
- 6,033,776 is suitable as a pipe wrap system, provided that the pipe is coated with a primer.
- Example 3 discloses the use of Escorez® 1315, a hydrocarbon resin having a number average molecular weight of about 950.
- this high shear pipeline tape has a number of disadvantages. First of all, it is required that a bare metal pipe if first coated with a liquid primer, preferably comprising a rubber and a tackifying resin. Secondly, the rubber-based adhesive layer of the tape comprises significant amounts of crosslinked material which is known to be detrimental for the self-healing properties of the rubber-based adhesive layer.
- WO 00/52381 of Raychem Ltd. discloses a further shrink sleeve for sealing a welding joint of insulated pipes, wherein between the end portions of the sleeve and the edges of the insulation a sealant or an adhesive is applied.
- the adhesive may be a polyamide based hot melt adhesive formulation.
- the sealant is preferably a blend of atactic polypropylene and polyisobutene, optionally with a tackfier, although other products are expressly said to be acceptable as well (cf. page 5, lines 15-17). The nature of the atactic polypropylene and the polyisobutene and their ratio is not disclosed.
- CA A 2.308.802 of Shaw Industries, Ltd. discloses a heat-shrinkable polyolefin shrink sleeve that can be applied on the bare welding joints of polypropylene coated pipelines.
- Polypropylene coatings which usually consist of a combination of epoxy/adhesive/polypropylene, are used for high temperature pipelines.
- an adhesive is necessary to bond the end edges of the shrink sleeve to the end edges of the propylene coatings to ensure a proper seal.
- CA A 2.308.802 therefore proposes to employ a two-component system for applying a heat-shrinkable polyolefin shrink sleeve to polypropylene coated pipelines.
- This two-component system comprises a functional coating (indicated by the reference number 21) and a bonding agent (indicated by the reference numbers 22 and 23).
- the functional coating adheres very well to the bare surface of the joint of the steel pipeline, but does not adhere to the polypropylene coating.
- the bonding agent which is applied between the edges of the functional coating and the propylene coating as can be seen in e.g. FIG. 2, adheres well to both coatings and provides a, although weak, water-resistant bond between the shrink sleeve and the polypropylene coating.
- the functional coating may be a mastic composition, a hot melt adhesive or a hybrid thereof, whereas the bonding agent is preferably a mastic composition.
- the mastic composition may comprise amorphous material or synthetic polymers or mixtures thereof.
- typical mastic compositions that are disclosed in CA A 2.308.802 are blends of substantially amorphous materials, e.g. butyl rubber, natural rubber and latex SBR rubber, and tackifying resins, e.g. synthetic hydrocarbon tackifying resins, rosin ester tackifying resins and inert fillers such as calcium carbonate, talc and carbon black.
- tackifying resins e.g. synthetic hydrocarbon tackifying resins, rosin ester tackifying resins and inert fillers such as calcium carbonate, talc and carbon black.
- These mastic compositions may further comprise other amorphous materials or synthetic polymers, e.g. asphalt, polybutene and amorphous polyolefins, e.g.
- U.S. Pat. No. 6,355,318 of Shawcor Ltd. also discloses a shrink sleeve based system for protecting welding joints of pre-isolated pipes.
- pre-isolated pipes are connected by welding the service pipe that extends beyond the insulation material, where after the welded joint is insulated encased by a shrink sleeve.
- An important requirement of such a shrink sleeve as already explained above is that it provides a water-tight connection and mechanical protection to the insulation and therefore should adhere very well to the insulation as well as to the pipe.
- an adhesive composition is applied between the edges of the insulation material and of the shrink sleeve.
- the nature of the adhesive composition is irrelevant since it may be selected from a wide range of materials, e.g. a sealant, a mastic or an hot melt adhesive. Obviously, this system suffers from the same disadvantages as the system disclosed in CA A 2.308.802.
- U.S. Pat. No. 6,589,346 of Bredero-Shaw Company discusses the technical problems encountered with protecting steel pipes and tubing for underground installation against corrosion.
- the usual method involves sandblasting the surface of the steel pipe, coating said surface with an epoxy coating and covering it with a polyolefin jacketing material like HDPE or PP.
- a polyolefin jacketing material like HDPE or PP.
- using a tape as jacketing material wherein the tape is spirally wound around the pipes, provides weak joints at the area of overlap and poor coverage of radial or longitudinal welding joints.
- spirally wrapped jacketing material is said to cause poor low temperature adhesion of the epoxy coating to the pipe.
- U.S. Pat. No. 6,465,547, U.S. Pat. No. 6,569,915 and U.S. Pat. No. 6,794,453, all of Shawcor Ltd. disclose coating or insulating crosslinked polypropylene compositions.
- U.S. Pat. No. 6,465,547 expressly discloses in column 1, lines 50-54, that polymers in which the predominant chain units comprise propylene or a higher olefin such as butene tend to depolymerise when exposed to free radicals to effect crosslinking. These patents are typically directed to crosslinked materials and heat-shrinkable articles made thereof.
- the invention disclosed in US 2004/0028862 is a patch comprising a dimensionally stable heat resistant fibrous backing layer and a layer of a high shear strength pressure sensitive adhesive which comprises a layer selected from the group consisting of isobutene polymers such as polyisobutene, polybutene and butyl rubber (butyl rubber is an elastomeric polymer based on about 98% isobutene and 2% isoprene and can easily be crosslinked as is well known in the art). It is expressly said that it is preferred that these materials are at least partially crosslinked to increase shear strength. Other preferred adhesive materials are silicones. Additionally, the nature or the properties of the polyisobutene are not disclosed.
- US 2004/0191515 to Mullen discloses an improved pipe coating for in particular subsea pipelines for the transportation of crude oil.
- such coatings consist of a protective epoxy-based protective coating that is applied on the steel pipe which is then covered with a marine concrete layer.
- the improved coating comprises a layer of polypropylene or polyethylene copolymer mixed with a polypropylene or polyethylene sintered material which is applied between the epoxy-based protective coating and the marine concrete layer to enhance shear resistance of the coating system.
- compositions comprising non-crosslinked material.
- U.S. Pat. No. 5,898,044 and US 2006175578 of Frans Nooren Afdichtingssystemen B.V. disclose a composition comprising an apolar, non-setting fluid polymer having a glass transition temperature lower than ⁇ 60° C., wherein the polymer has a surface tension of less than 40 mN/m above the glass transition temperature and one or more fillers.
- the corrosion protective coating systems disclosed in the prior art are in particular hampered by the fact that many materials are used or even have to be used that lack a good compatibility. Often, adhesive systems must be used that adhere very well to some materials, but not to others, with the consequence that even different adhesive systems must be used within the same corrosion protective coating system. There is therefore a need in the art for an adhesive composition that is widely applicable and has an excellent compatibility with the common materials used in corrosion protective coating systems and with the materials used for the construction of the pipes, pipelines and the like, e.g. steel, metal and concrete.
- the present invention provides an adhesive composition based on one or more particular polyisobutenes.
- This adhesive composition has an excellent compatibility with materials used in corrosion protections, e.g. shrink sleeves and shrink patches made of polyolefins and polymeric compositions comprising non-crosslinked polymers and fillers.
- the present invention therefore relates to a process for providing an extended tubular article or one or more sections of the extended tubular article with a corrosion protecting system, wherein (a) a layer of an adhesive composition is applied to the surface of the extended tubular article or the one or more sections of the extended tubular article, and (b) a corrosion protecting layer is applied to the layer of the adhesive composition, the adhesive composition comprising a polyolefin blend, wherein the polyolefin blend comprises 30% to 100% by weight of a polyisobutene and 0% to 70% by weight of an olefin polymer, based on the total weight of the polyolefin blend, wherein said polyisobutene is characterised by:
- (B) a number average molecular weight M n of 1300 to 1,000,000.
- the adhesive composition comprises a single polyisobutene or a blend of different polyisobutenes.
- the glass transition temperature or glass transition temperatures of the polyisobutenes are preferably lower than ⁇ 50° C. and more preferably lower than ⁇ 60° C.
- the glass transition temperature or glass transition temperatures can be determined by differential scanning caloriemetry (DSC) as is well known in the art.
- the number average molecular weight M n is preferably within the range of 5,000 to 1,000,000, more preferably within the range of 10,000 to 1,000,000 and in particular within the range of 10,000 to 900,000.
- the molecular weight distribution M w /M n of the polyisobutenes is preferably between 1 to 10, more preferably 1 to 5, even more preferably 1 to 4 and most preferably 1.5 to 3.5.
- the number average molecular weight M n of the polyisobutenes is determined by GPC for the lower molecular weights, e.g. up to about 100,000.
- the higher number average molecular weights they are determined by viscosity measurements (Staudinger Index J o , formerly known as intrinsic viscosity), wherein the Staudinger Index is calculated from the flow time at 20° C. through capillary 1 of an Ubbelohde viscometer using the following formulas:
- t is the flow time of the solution, with Hagenbach-Couette correction, to is the flow time of the solvent (e.g. isooctane), with Hagenbach-Couette correction, and c is the concentration if the solution in g/cm 3 .
- the number average molecular weight M n is then calculated as follows:
- the polyisobutenes to be used in the adhesive composition according to the present invention preferably have a Staudinger Index J o of 10 to 1500 cm 3 /g, preferably of 20 to 1000 cm 3 /g, as determined at 20° C.
- the polyisobutenes have further preferably a surface tension of less than 40 mN/m at 20° C.
- the density of the polyisobutenes is preferably between 0.90 to 0.95 g/cm 3 .
- the polyisobutenes may be prepared in various ways. Polymerisation may be conducted in single stage processes or in multi stage processes. It is preferred that the polymerisation is conducted in the liquid phase using a Lewis acid as catalyst, preferably boron trifluoride complex catalyst, optionally in the presence of a cocatalyst. Such processes are well known in the art.
- Preferred polyisobutenes are from the Oppanol series, in particular from the Oppanol B type.
- the olefin polymer is preferably selected from the group consisting of (a) a polymer comprising 50.0% to 99.9% by weight of isobutene and 0.1% to 50.0% of an optionally substituted, linear or branched C 2 -C 12 alkene or an optionally substituted, linear or branched C 2 -C 12 alkadiene, based on the total weight of the polymer, (b) a polymer comprising 50.0% to 99.9% by weight of propene and 0.1% to 50.0% of a an optionally substituted, linear or branched C 2 -C 12 alkene, based on the total weight of the polymer, (c) a polymer comprising 0.1% to 50.0% by weight of ethene and 50.0% to 99.9% of an optionally substituted, linear or branched C 2 -C 12 alkene, based on the total weight of the polymer, (d) a polymer comprising 0.1% to 50.0% by weight of ethen
- the olefin polymer is uncrosslinked.
- olefin polymers according to class (a) include polybutenes manufactured from a butene feed (such feeds comprise 1-butene and isobutene or 1-butene and small amounts of ethene, propene or other C 4 -C 6 ⁇ -olefins), butyl rubbers (copolymers of about 98 wt. % isobutene and 2 wt. % isoprene), halogenated butyl rubbers, copolymers of isobutene and butadiene and the like.
- Examples of the olefin polymers according to class (b) include atactic polypropenes, ethene/propene copolymers, in particular those having a high propene content and ethene/propene/diene copolymers.
- Examples of the olefin polymers according to class (c) include ethene copolymers having as a comonomer e.g. propene, 1-hexene, 1-octene and 1-decene.
- An example of the olefin polymer of class (d) includes poly(2-methyl-1pentene).
- the olefin polymer is selected from the group consisting of polybutene, butyl rubber, atactic polypropylene, poly(2-methyl-1-pentene) and mixtures thereof.
- the polybutene has preferably a melt index of 0.2-300 g/min (ISO 1133; 190° C., 2.16 kg), a density of 0.90-0.95 g/cm 3 (ISO 1183) and a melting point of 80°-130° C. according to DSC.
- the butyl rubber ahs preferably a Mooney viscosity ML 1+8 (ASTM D 1646; 125° C.) of 25 to 75 and a level of unsaturation of 1.0 to 3.0 mol %.
- the poly(2-methyl-1-pentene) has preferably a melt index of 1-250 g/min (ASTM D 1236, 260° C., 5 kg), a softening point of 160°-200° C. (Vicat, ASTM D 1525) and a density of 0.82-0.85 g/cm 3 at 25° C.
- the atactic polypropylene has preferably a number average molecular weight of 1,000-3,000 and a weight average molecular weight of 100,000-200,000.
- the amount of C 2 -C 10 ⁇ -olefin is up to about 20 percent by weight, and is preferably between about 2 and about 10 percent by weight.
- the olefin polymer has a glass transition temperature of less then ⁇ 20° C., more preferably less than ⁇ 40° and most preferably less than ⁇ 60° C. Additionally, it is preferred that the olefin polymer has a surface tension of less than 40 mN/m at 20° C.
- the adhesive composition preferably comprises 50% to 100% by weight of a polyisobutene and 0% to 50% by weight of the olefin polymer, based on the total weight of the polyolefin blend. More preferably, the adhesive composition comprises 75% to 100% by weight of a polyisobutene and 0% to 25% by weight of the olefin polymer, based on the total weight of the polyolefin blend. Even more preferably, the adhesive composition preferably comprises 90% to 100% by weight of a polyisobutene and 0% to 10% of the olefin polymer, based on the total weight of the polyolefin blend. Most preferably, the adhesive composition comprises 100% by weight of a polyisobutene and no olefin polymer.
- a layer of the adhesive composition according to the present invention is applied to the surface of the extended tubular article or the one or more sections of the extended tubular article with a thickness of 0.01 mm to 50 mm, preferable 0.1 mm to 25 mm.
- the surface of the extended tubular articles does not need any pre-treatment, e.g. sandblasting or treatments with hazardous and environmentally unfriendly chemicals such as phosphoric acid and chromate.
- some pre-treatments may enhance the adhesive properties of the adhesive composition.
- the extended tubular article may comprise a base layer of a pre-coat, e.g. a pre-coat based on an epoxy resin.
- the extended tubular article may have as base layer a polyolefin layer.
- one application of the adhesive composition is the use thereof in a process for manufacturing pre-coated steel pipes wherein the pipes are provided with a pre-coating, preferably a polyolefin coating, preferably a polyethene or a polypropene coating.
- the extended tubular article is therefore a pipe or a pipe line or a section thereof, in particular joints.
- the pipe or pipe line is essentially made of steel or concrete, most preferably of steel.
- the adhesive composition according to the present invention is compatible with and adheres extremely well to materials commonly used in corrosion protective systems. Even compositions such as disclosed in U.S. Pat. No. 5,898,044 and US 2006175578 of Frans Nooren Afdichtingssystemen B.V. appear to have a better adhesion to the object to be protected.
- another application of the adhesive composition according to the present invention is the use thereof in a method for protecting a shaped article, preferably an oil or gas line or pipe, against corrosion, wherein in a first step a first layer of the adhesive composition according to the present invention is applied to the surface of the shaped article and wherein in a second step a second layer of a corrosion protective composition is applied to the layer of the adhesive composition according to the present invention, wherein the composition comprises:
- the filler material comprises an inorganic material such as inorganic minerals, salts and oxides, e.g. chalk, boron sulphate, aluminium oxide, silicon dioxide, limestone, ground quartz, glass, talc, slate, bentonite and the like. It is also preferred that the filler material has a density of about 2.0 to about 4.0 kg/dm 3 , preferably about 1.5 to about 3.5 kg/dm 3 , at 20° C. according to DIN ISO 787/10. It is furthermore preferred that the filler material consists essentially of an inorganic material, preferably at least 75 wt. %, more preferably at least 90 wt. % and most preferably at least 95 wt.
- inorganic material such as inorganic minerals, salts and oxides, e.g. chalk, boron sulphate, aluminium oxide, silicon dioxide, limestone, ground quartz, glass, talc, slate, bentonite and the like. It is also preferred that the filler material has a density of about
- the filler material has a very low water solubility, preferably of less than 0.1 g/l (20° C.; according to DIN ISO 787/8), more preferably less than 0.05 g/l.
- the filler material consists essentially of calcium carbonate and a very suitable commercially available material is Omyalite 95T (available from Omya GmbH, GmbH, Germany).
- the composition used for the second layer preferably comprises about 40 wt. % to about 80 wt. % of the filler material, preferably about 50 wt. % to about 70 wt. %, calculated on the total weight of the corrosion protecting system.
- the primary anti-oxidant is selected from the group consisting of sterically hindered phenol compounds. More preferably, the anti-oxidant is an anti-oxidant composition comprising at least two anti-oxidants, wherein it is preferred that the anti-oxidant composition comprises a primary anti-oxidant and a secondary anti-oxidant. Additionally, the sterically hindered phenol compound preferably comprises at least two sterically hindered phenol groups. Furthermore, the secondary anti-oxidant is selected from the group consisting of fosfites and thioesters. The anti-oxidant composition further comprises a lactone. Such anti-oxidants are extensively disclosed in WO 2005/005528 which for that reason is expressly incorporated by reference.
- the second layer of the corrosion protective composition comprising at least one polyisobutene, filler and anti-oxidant is provided with a third layer, said third layer being a film comprising an olefinic polymer or copolymer.
- the first layer may be provided with a top layer formed by a wrapping tape, said wrapping tape comprising a first layer comprising the film comprising the olefinic polymer or copolymer and a second layer comprising the composition comprising at least one polyisobutene, filler and anti-oxidant and having a total thickness of about 1.0 to about 3.0 cm, more preferably about 1.2 to about 2.8 cm.
- the second layer of the composition comprising at least one polyisobutene, filler and anti-oxidant is enclosed by a shrink sleeve or wrap-around sleeve or sheet which are well known in the art.
- extended tubular articles or sections thereof e.g. a pipe or a pipe line or a section thereof, that are connected to each other by connecting means or structures such as joints and flanges, wherein these connecting means or structures and the extended tubular articles do not have a gradual transition
- a non-hardening composition consisting essentially of the polyisobutene and the filler material described above is preferably used to create a gradual transition.
- the advantage of applying such a non-hardening composition is that the combination of the corrosive protecting composition described above and the third layer, e.g. the film or the wrapping tape, can more easily be wrapped around the transition of extended tubular article and connecting means or structure.
- This non-hardening composition contains essentially about 90-99% by weight of the polyisobutene and 1-10% by weight of the filler material.
- This non-hardening composition may be applied below to the first layer of the adhesive composition, between said first layer of the adhesive composition and the second layer of the corrosive protective composition or between said second layer of the corrosive protective composition and the third layer of the corrosion protecting layer disclosed below.
- the corrosion protecting layer which is applied to the surface of the adhesive composition comprises a polyolefin material, preferably a homopolymer or a copolymer of an optionally substituted, linear or branched C 2 -C 12 alkene.
- the corrosion protecting layer according to this invention is heat shrinkable. More preferably, this corrosion protecting layer comprises a shrink sleeve or a wrap-around sleeve or sheet as is disclosed above.
- the corrosion protecting layer comprises the composition disclosed above which comprises a polyisobutene having a glass transition temperature of less than ⁇ 20° C. and surface tension of less than 40 mM/m at a temperature above the glass transition temperature of said polyisobutene; a filler material; and an anti-oxidant, wherein said anti-oxidant is selected from the group consisting of a primary and a secondary anti-oxidant.
- the adhesive composition according to the present invention is in particular useful in the following methods for providing corrosion protection.
- a high shear adhesive tape comprising a backing material may carry on the surface thereof a layer of the adhesive composition according to the present invention, wherein the backing material comprises an impact resistant polymeric material that is preferably made of a polyolefin.
- the high shear adhesive tape can be wound around an extended tubular article or a part thereof, e.g. a welded joint.
- the backing material of the high shear adhesive tape preferably comprises an impact resistant polymeric material.
- the high shear adhesive tape has preferably a totals thickness of 5-30 mils.
- a layer of the adhesive composition according to the present invention may be applied to (a part of) the propylene covering to bond a second covering, in particular where heat shrinkable sleeves are to be provided onto such propylene coverings as is disclosed in e.g. CA A 2.308.802.
- the adhesive composition according to the present invention may be used in a method for forming a composite sleeve having heat shrinkable end portions, wherein an inner covering member is disposed on a mandrel and a sleeve is disposed around the inner member and the mandrel, wherein the sleeve extends beyond both ends of the inner member.
- the sleeve is manufactured from a heat shrinkable sheet having end portions which are to be bonded together at an overlapping portion. Subsequently, the sleeve is heat shrunk so that the sleeve is bonded to the inner member to form the composite sleeve.
- the adhesive composition according to the present invention may be applied to the edges of the insulation and/or to the edges of the sleeve to ensure not only a good bond between the two, but also a water tight seal.
- the adhesive composition according to the present invention may be used to apply a closure comprising a heat resistant backing layer, wherein to a surface of the backing layer a layer of the adhesive composition is applied, to a heat shrinkable wrap around sleeve.
- the closure is applied to the overlapping sections of the wrap around sleeve prior to heat shrinking to prevent slippage of the overlapping sections during heat shrinking and to prevent subsequent creeping of the overlap joint.
- the adhesive composition according to the present invention may also be used to improve the bonding between epoxy base layers provided on pipes and pipelines and outer coatings, e.g. marine concrete.
- Adhesive Composition Comprising Filler Material
- the adhesive composition according to the present invention may also comprise a filler material, which is preferably an active reinforcing filler, preferably a fumed silica, e.g. AEROSIL® available from Degussa.
- a fumed silica e.g. AEROSIL® available from Degussa.
- the adhesive composition comprises about 1 to about 10 percent by weight of the filler material, based on the total weight of the adhesive composition.
Abstract
The present invention provides a system, composition and process for protecting an extended tubular article or a section thereof from corrosion. The system comprises a layer of an adhesive composition on a surface of the extended tubular article or section thereof, and a corrosion protecting layer thereon.
Description
- The present invention relates to a process for providing a pipe, pipeline or a part thereof with a coating system having self-repairing properties to protect the pipe, pipeline or part thereof against corrosion and other harmful and degradative effects, including environmental forces that impact the lifetime and operation of the pipe, pipeline or part thereof.
- In the prior art many corrosion protective coating systems are disclosed and many of those corrosion protective coating systems are commercialised. Although various systems may have certain advantages over others, most of them have serious drawbacks. Common corrosion protecting systems comprise coating systems, optionally comprising various layers of materials, shrink sleeves, and tapes, optionally provided with adhesive layers, and combinations of such systems.
- U.S. Pat. No. 5,817,413 and its Continuation-In-Part U.S. Pat. No. 6,033,776, both of Scapa Tapes North America, for example, disclose a high shear pipeline tape comprising a backing material having on one surface thereof a rubber-based adhesive layer. The rubber-based adhesive layer comprises a rubber mix and a tackifying resin. The rubber mix comprises crosslinked halogenated rubber, non-crosslinked rubber and a styrenic blockpolymer or terpolymer, e.g. a Kraton® polymer. The non-crosslinked rubber is preferably butyl rubber, preferably a mixture of virgin butyl rubber and recycled butyl rubber (butyl rubber is a copolymers of about 98 wt. % isobutene and 2 wt. % isoprene). The tackifying resin is used to provide the desired adhesiveness to the rubber mix and may be selected from a very large group of materials, e.g. rosins, modified rosins, rosin esters, polymerised petroleum hydrocarbons, polymerised terpenes and various resins. Examples 1 and 2 disclose formulations comprising different tackifiers, e.g. Endex® 155 (an aromatic hydrocarbon resin available from Eastman Chemical Company, Indopol® H-100 (an isobutene/1-butene copolymer having a number average molecular weight of about 910, formally available from British Petroleum Chemicals, but currently available from e.g. Amoco Chemical Company and Innovene), Escorez® 1102 (an aliphatic hydrocarbon resin having an average molecular weight of about 1300, available from ExxonMobil), and Piccopale® 100 (a polyterpene resin). Escorez® 1102 is made by polymerising petroleum fractions having a boiling point from about 15° C. to about 410° C. at atmospheric pressure which are formed by the thermal cracking of petroleum feedstock. The fractions may be polymerised thermally or in the presence of a catalyst, for example a Friedel-Crafts catalyst such as AlCl3. Usually the petroleum feedstock, e.g. light naphtha, heavy naphtha, kerosene, gas oil, vacuum gas oil and comprising C5 olefins and diolefins, C6 olefins and diolefins or a mixture of C5 and C6 olefines and diolefins, is cracked in the presence of steam. The products from this cracking process usually have a boiling point of −15° C. to 280° C. and may comprise about 30 to 60% olefins, 10 to 30% diolefins, 20 to 50% aromatics and 5 to 20% paraffins and naphthalenes. Preferably the product is subjected to fractionation to remove C2 to C4 light ends, thermal soaking and distillation to remove hydrocarbons such as cyclic diolefins including cyclopentadiene and methyl cyclopentadiene as dimers (cf. U.S. Pat. No. 4,690,958). Consequently, Escorez® 1102 and 1315 (see below) are not isobutene based polymers. The high shear tape according to U.S. Pat. No. 5,817,413 and U.S. Pat. No. 6,033,776 is suitable as a pipe wrap system, provided that the pipe is coated with a primer. Example 3 discloses the use of Escorez® 1315, a hydrocarbon resin having a number average molecular weight of about 950. However, this high shear pipeline tape has a number of disadvantages. First of all, it is required that a bare metal pipe if first coated with a liquid primer, preferably comprising a rubber and a tackifying resin. Secondly, the rubber-based adhesive layer of the tape comprises significant amounts of crosslinked material which is known to be detrimental for the self-healing properties of the rubber-based adhesive layer.
- WO 00/52381 of Raychem Ltd. discloses a further shrink sleeve for sealing a welding joint of insulated pipes, wherein between the end portions of the sleeve and the edges of the insulation a sealant or an adhesive is applied. The adhesive may be a polyamide based hot melt adhesive formulation. The sealant is preferably a blend of atactic polypropylene and polyisobutene, optionally with a tackfier, although other products are expressly said to be acceptable as well (cf. page 5, lines 15-17). The nature of the atactic polypropylene and the polyisobutene and their ratio is not disclosed.
- CA A 2.308.802 of Shaw Industries, Ltd., discloses a heat-shrinkable polyolefin shrink sleeve that can be applied on the bare welding joints of polypropylene coated pipelines. Polypropylene coatings which usually consist of a combination of epoxy/adhesive/polypropylene, are used for high temperature pipelines. For applying such a heat-shrinkable polyolefin shrink sleeve to the welding joints of the polypropylene coated pipes, an adhesive is necessary to bond the end edges of the shrink sleeve to the end edges of the propylene coatings to ensure a proper seal. However, common high strength adhesives used for this purpose suffer from the disadvantage that they usually bond well to the polyolefin shrink sleeve, but not to the propylene coating. On the other hand, other adhesives that do bond well to the polyolefin shrink sleeve as well as to the polypropylene coating, i.e. low strength mastic compositions, suffer from the disadvantage that they have insufficient shear resistance, in particular at elevated temperatures. CA A 2.308.802 therefore proposes to employ a two-component system for applying a heat-shrinkable polyolefin shrink sleeve to polypropylene coated pipelines. This two-component system comprises a functional coating (indicated by the reference number 21) and a bonding agent (indicated by the reference numbers 22 and 23). The functional coating adheres very well to the bare surface of the joint of the steel pipeline, but does not adhere to the polypropylene coating. On the other hand, the bonding agent, which is applied between the edges of the functional coating and the propylene coating as can be seen in e.g. FIG. 2, adheres well to both coatings and provides a, although weak, water-resistant bond between the shrink sleeve and the polypropylene coating. The functional coating may be a mastic composition, a hot melt adhesive or a hybrid thereof, whereas the bonding agent is preferably a mastic composition. The mastic composition may comprise amorphous material or synthetic polymers or mixtures thereof. Examples of typical mastic compositions that are disclosed in CA A 2.308.802 are blends of substantially amorphous materials, e.g. butyl rubber, natural rubber and latex SBR rubber, and tackifying resins, e.g. synthetic hydrocarbon tackifying resins, rosin ester tackifying resins and inert fillers such as calcium carbonate, talc and carbon black. These mastic compositions may further comprise other amorphous materials or synthetic polymers, e.g. asphalt, polybutene and amorphous polyolefins, e.g. amorphous polypropylene, styrene-isoprene copolymers and liquid butyl polymers. Obviously, the protective system disclosed in CA A 2.308.802 is highly complex and requires many different types of materials. Moreover, shrink sleeves in general suffer from the disadvantage that they do not have self-healing properties.
- U.S. Pat. No. 6,355,318 of Shawcor Ltd. also discloses a shrink sleeve based system for protecting welding joints of pre-isolated pipes. In the field, pre-isolated pipes are connected by welding the service pipe that extends beyond the insulation material, where after the welded joint is insulated encased by a shrink sleeve. An important requirement of such a shrink sleeve as already explained above is that it provides a water-tight connection and mechanical protection to the insulation and therefore should adhere very well to the insulation as well as to the pipe. To that end, an adhesive composition is applied between the edges of the insulation material and of the shrink sleeve. The nature of the adhesive composition is irrelevant since it may be selected from a wide range of materials, e.g. a sealant, a mastic or an hot melt adhesive. Obviously, this system suffers from the same disadvantages as the system disclosed in CA A 2.308.802.
- U.S. Pat. No. 6,589,346 of Bredero-Shaw Company discusses the technical problems encountered with protecting steel pipes and tubing for underground installation against corrosion. The usual method involves sandblasting the surface of the steel pipe, coating said surface with an epoxy coating and covering it with a polyolefin jacketing material like HDPE or PP. In particular with small diameter pipes, it is difficult to provide a uniform coating of the epoxy coating. Secondly, using a tape as jacketing material, wherein the tape is spirally wound around the pipes, provides weak joints at the area of overlap and poor coverage of radial or longitudinal welding joints. Furthermore, spirally wrapped jacketing material is said to cause poor low temperature adhesion of the epoxy coating to the pipe.
- U.S. Pat. No. 6,465,547, U.S. Pat. No. 6,569,915 and U.S. Pat. No. 6,794,453, all of Shawcor Ltd., disclose coating or insulating crosslinked polypropylene compositions. U.S. Pat. No. 6,465,547 expressly discloses in column 1, lines 50-54, that polymers in which the predominant chain units comprise propylene or a higher olefin such as butene tend to depolymerise when exposed to free radicals to effect crosslinking. These patents are typically directed to crosslinked materials and heat-shrinkable articles made thereof.
- Another shrink sleeve system is disclosed in US 2004/0028862 to Burwell et al. In particular, this patent application is directed to joining and sealing overlapping edges of heat shrinkable polymeric wrap-around sleeves. Such sleeves comprise an outer layer of heat shrinkable polyolefin material and an inner layer of an adhesive, which adheres the sleeve to the substrate. The sleeve is wrapped around the welding joint of a pipeline, subsequently heated to cause shrinkage of the sleeve. Prior to the heat shrinking step, the overlapping edges of the sleeve are covered by a patch to prevent slippage of the overlapping ends during heat shrinking and subsequent creeping of the overlap joint. The invention disclosed in US 2004/0028862 is a patch comprising a dimensionally stable heat resistant fibrous backing layer and a layer of a high shear strength pressure sensitive adhesive which comprises a layer selected from the group consisting of isobutene polymers such as polyisobutene, polybutene and butyl rubber (butyl rubber is an elastomeric polymer based on about 98% isobutene and 2% isoprene and can easily be crosslinked as is well known in the art). It is expressly said that it is preferred that these materials are at least partially crosslinked to increase shear strength. Other preferred adhesive materials are silicones. Additionally, the nature or the properties of the polyisobutene are not disclosed.
- US 2004/0191515 to Mullen, discloses an improved pipe coating for in particular subsea pipelines for the transportation of crude oil. Usually, such coatings consist of a protective epoxy-based protective coating that is applied on the steel pipe which is then covered with a marine concrete layer. The improved coating comprises a layer of polypropylene or polyethylene copolymer mixed with a polypropylene or polyethylene sintered material which is applied between the epoxy-based protective coating and the marine concrete layer to enhance shear resistance of the coating system.
- Commercial processes to produce pre-coated steel pipes are very complex and are environmentally unfriendly. First of all, the surface of the steel pipes must be thoroughly cleaned by sandblasting and treatment with acids such as phosphoric acid and chromate. The steel pipe is then heated to a particular material. Subsequently, a primer is applied, usually an epoxy coating. Further layers to improve the protection can be applied, e.g. polyolefin coatings or layers having at least one surface thereof coated with an adhesive composition.
- Other corrosion protective systems are based on compositions comprising non-crosslinked material. For example, U.S. Pat. No. 5,898,044 and US 2006175578 of Frans Nooren Afdichtingssystemen B.V. disclose a composition comprising an apolar, non-setting fluid polymer having a glass transition temperature lower than −60° C., wherein the polymer has a surface tension of less than 40 mN/m above the glass transition temperature and one or more fillers.
- The corrosion protective coating systems disclosed in the prior art are in particular hampered by the fact that many materials are used or even have to be used that lack a good compatibility. Often, adhesive systems must be used that adhere very well to some materials, but not to others, with the consequence that even different adhesive systems must be used within the same corrosion protective coating system. There is therefore a need in the art for an adhesive composition that is widely applicable and has an excellent compatibility with the common materials used in corrosion protective coating systems and with the materials used for the construction of the pipes, pipelines and the like, e.g. steel, metal and concrete.
- The present invention provides an adhesive composition based on one or more particular polyisobutenes. This adhesive composition has an excellent compatibility with materials used in corrosion protections, e.g. shrink sleeves and shrink patches made of polyolefins and polymeric compositions comprising non-crosslinked polymers and fillers. The present invention therefore relates to a process for providing an extended tubular article or one or more sections of the extended tubular article with a corrosion protecting system, wherein (a) a layer of an adhesive composition is applied to the surface of the extended tubular article or the one or more sections of the extended tubular article, and (b) a corrosion protecting layer is applied to the layer of the adhesive composition, the adhesive composition comprising a polyolefin blend, wherein the polyolefin blend comprises 30% to 100% by weight of a polyisobutene and 0% to 70% by weight of an olefin polymer, based on the total weight of the polyolefin blend, wherein said polyisobutene is characterised by:
- (A) a glass transition temperature of lower than −40° C.; and
- (B) a number average molecular weight Mn of 1300 to 1,000,000.
- In this description and in its claims, the verb “to comprise” and its conjugations is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. In addition, reference to an element by the indefinite article “a” or “an” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there is one and only one of the elements. The indefinite article “a” or “an” thus usually means “at least one”.
- The adhesive composition comprises a single polyisobutene or a blend of different polyisobutenes. The glass transition temperature or glass transition temperatures of the polyisobutenes are preferably lower than −50° C. and more preferably lower than −60° C. The glass transition temperature or glass transition temperatures can be determined by differential scanning caloriemetry (DSC) as is well known in the art.
- The number average molecular weight Mn is preferably within the range of 5,000 to 1,000,000, more preferably within the range of 10,000 to 1,000,000 and in particular within the range of 10,000 to 900,000. The molecular weight distribution Mw/Mn of the polyisobutenes is preferably between 1 to 10, more preferably 1 to 5, even more preferably 1 to 4 and most preferably 1.5 to 3.5.
- The number average molecular weight Mn of the polyisobutenes is determined by GPC for the lower molecular weights, e.g. up to about 100,000. For the higher number average molecular weights, they are determined by viscosity measurements (Staudinger Index Jo, formerly known as intrinsic viscosity), wherein the Staudinger Index is calculated from the flow time at 20° C. through capillary 1 of an Ubbelohde viscometer using the following formulas:
-
J o=ηsp /c(1+0.31×ηsp)[cm3/g] -
ηsp=(t/t o)−1 - wherein t is the flow time of the solution, with Hagenbach-Couette correction, to is the flow time of the solvent (e.g. isooctane), with Hagenbach-Couette correction, and c is the concentration if the solution in g/cm3. The number average molecular weight Mn is then calculated as follows:
-
- The polyisobutenes to be used in the adhesive composition according to the present invention preferably have a Staudinger Index Jo of 10 to 1500 cm3/g, preferably of 20 to 1000 cm3/g, as determined at 20° C.
- The polyisobutenes have further preferably a surface tension of less than 40 mN/m at 20° C. The density of the polyisobutenes is preferably between 0.90 to 0.95 g/cm3.
- The polyisobutenes may be prepared in various ways. Polymerisation may be conducted in single stage processes or in multi stage processes. It is preferred that the polymerisation is conducted in the liquid phase using a Lewis acid as catalyst, preferably boron trifluoride complex catalyst, optionally in the presence of a cocatalyst. Such processes are well known in the art.
- Preferred polyisobutenes are from the Oppanol series, in particular from the Oppanol B type.
- According to the present invention, the olefin polymer is preferably selected from the group consisting of (a) a polymer comprising 50.0% to 99.9% by weight of isobutene and 0.1% to 50.0% of an optionally substituted, linear or branched C2-C12 alkene or an optionally substituted, linear or branched C2-C12 alkadiene, based on the total weight of the polymer, (b) a polymer comprising 50.0% to 99.9% by weight of propene and 0.1% to 50.0% of a an optionally substituted, linear or branched C2-C12 alkene, based on the total weight of the polymer, (c) a polymer comprising 0.1% to 50.0% by weight of ethene and 50.0% to 99.9% of an optionally substituted, linear or branched C2-C12 alkene, based on the total weight of the polymer, (d) a polymer comprising 0.1% to 50.0% by weight of 2-methyl-1-pentene and 50.0% to 99.9% of an optionally substituted, linear or branched C2-C12 alkene, based on the total weight of the polymer, and mixtures thereof. Preferably, the olefin polymer is uncrosslinked. Examples of olefin polymers according to class (a) include polybutenes manufactured from a butene feed (such feeds comprise 1-butene and isobutene or 1-butene and small amounts of ethene, propene or other C4-C6 α-olefins), butyl rubbers (copolymers of about 98 wt. % isobutene and 2 wt. % isoprene), halogenated butyl rubbers, copolymers of isobutene and butadiene and the like. Examples of the olefin polymers according to class (b) include atactic polypropenes, ethene/propene copolymers, in particular those having a high propene content and ethene/propene/diene copolymers. Examples of the olefin polymers according to class (c) include ethene copolymers having as a comonomer e.g. propene, 1-hexene, 1-octene and 1-decene. An example of the olefin polymer of class (d) includes poly(2-methyl-1pentene).
- Most preferably, the olefin polymer is selected from the group consisting of polybutene, butyl rubber, atactic polypropylene, poly(2-methyl-1-pentene) and mixtures thereof.
- The polybutene has preferably a melt index of 0.2-300 g/min (ISO 1133; 190° C., 2.16 kg), a density of 0.90-0.95 g/cm3 (ISO 1183) and a melting point of 80°-130° C. according to DSC.
- The butyl rubber ahs preferably a Mooney viscosity ML 1+8 (ASTM D 1646; 125° C.) of 25 to 75 and a level of unsaturation of 1.0 to 3.0 mol %.
- The poly(2-methyl-1-pentene) has preferably a melt index of 1-250 g/min (ASTM D 1236, 260° C., 5 kg), a softening point of 160°-200° C. (Vicat, ASTM D 1525) and a density of 0.82-0.85 g/cm3 at 25° C.
- The atactic polypropylene has preferably a number average molecular weight of 1,000-3,000 and a weight average molecular weight of 100,000-200,000. In the atactic polypropylene, the amount of C2-C10 α-olefin is up to about 20 percent by weight, and is preferably between about 2 and about 10 percent by weight.
- According to the invention, it is preferred that the olefin polymer has a glass transition temperature of less then −20° C., more preferably less than −40° and most preferably less than −60° C. Additionally, it is preferred that the olefin polymer has a surface tension of less than 40 mN/m at 20° C.
- The adhesive composition preferably comprises 50% to 100% by weight of a polyisobutene and 0% to 50% by weight of the olefin polymer, based on the total weight of the polyolefin blend. More preferably, the adhesive composition comprises 75% to 100% by weight of a polyisobutene and 0% to 25% by weight of the olefin polymer, based on the total weight of the polyolefin blend. Even more preferably, the adhesive composition preferably comprises 90% to 100% by weight of a polyisobutene and 0% to 10% of the olefin polymer, based on the total weight of the polyolefin blend. Most preferably, the adhesive composition comprises 100% by weight of a polyisobutene and no olefin polymer.
- According to the invention, a layer of the adhesive composition according to the present invention is applied to the surface of the extended tubular article or the one or more sections of the extended tubular article with a thickness of 0.01 mm to 50 mm, preferable 0.1 mm to 25 mm.
- An important advantage of the adhesive composition according to the present invention is that the surface of the extended tubular articles does not need any pre-treatment, e.g. sandblasting or treatments with hazardous and environmentally unfriendly chemicals such as phosphoric acid and chromate. However, some pre-treatments may enhance the adhesive properties of the adhesive composition. For instance, the extended tubular article may comprise a base layer of a pre-coat, e.g. a pre-coat based on an epoxy resin. In another embodiment of the present invention, the extended tubular article may have as base layer a polyolefin layer. Consequently, one application of the adhesive composition is the use thereof in a process for manufacturing pre-coated steel pipes wherein the pipes are provided with a pre-coating, preferably a polyolefin coating, preferably a polyethene or a polypropene coating.
- The applications of the adhesive composition is, in particular, in the field of corrosion protection. Consequently, according to the invention, the extended tubular article is therefore a pipe or a pipe line or a section thereof, in particular joints. Furthermore, it is preferred that the pipe or pipe line is essentially made of steel or concrete, most preferably of steel.
- The adhesive composition according to the present invention is compatible with and adheres extremely well to materials commonly used in corrosion protective systems. Even compositions such as disclosed in U.S. Pat. No. 5,898,044 and US 2006175578 of Frans Nooren Afdichtingssystemen B.V. appear to have a better adhesion to the object to be protected. Hence, another application of the adhesive composition according to the present invention is the use thereof in a method for protecting a shaped article, preferably an oil or gas line or pipe, against corrosion, wherein in a first step a first layer of the adhesive composition according to the present invention is applied to the surface of the shaped article and wherein in a second step a second layer of a corrosion protective composition is applied to the layer of the adhesive composition according to the present invention, wherein the composition comprises:
- (a) a polyisobutene having a glass transition temperature of less than −20° C. and surface tension of less than 40 mM/m at a temperature above the glass transition temperature of said polyisobutene,
- (b) a filler material, and
- (c) an anti-oxidant, wherein said anti-oxidant is selected from the group consisting of a primary and a secondary anti-oxidant.
- In this embodiment of the invention, it is preferred that the filler material comprises an inorganic material such as inorganic minerals, salts and oxides, e.g. chalk, boron sulphate, aluminium oxide, silicon dioxide, limestone, ground quartz, glass, talc, slate, bentonite and the like. It is also preferred that the filler material has a density of about 2.0 to about 4.0 kg/dm3, preferably about 1.5 to about 3.5 kg/dm3, at 20° C. according to DIN ISO 787/10. It is furthermore preferred that the filler material consists essentially of an inorganic material, preferably at least 75 wt. %, more preferably at least 90 wt. % and most preferably at least 95 wt. %, based on the total weight of the filler material. It is furthermore preferred that the filler material has a very low water solubility, preferably of less than 0.1 g/l (20° C.; according to DIN ISO 787/8), more preferably less than 0.05 g/l. According to a particular embodiment of the present invention, the filler material consists essentially of calcium carbonate and a very suitable commercially available material is Omyalite 95T (available from Omya GmbH, Köln, Germany). The composition used for the second layer preferably comprises about 40 wt. % to about 80 wt. % of the filler material, preferably about 50 wt. % to about 70 wt. %, calculated on the total weight of the corrosion protecting system.
- In addition, according to this embodiment of the invention, it is furthermore preferred that the primary anti-oxidant is selected from the group consisting of sterically hindered phenol compounds. More preferably, the anti-oxidant is an anti-oxidant composition comprising at least two anti-oxidants, wherein it is preferred that the anti-oxidant composition comprises a primary anti-oxidant and a secondary anti-oxidant. Additionally, the sterically hindered phenol compound preferably comprises at least two sterically hindered phenol groups. Furthermore, the secondary anti-oxidant is selected from the group consisting of fosfites and thioesters. The anti-oxidant composition further comprises a lactone. Such anti-oxidants are extensively disclosed in WO 2005/005528 which for that reason is expressly incorporated by reference.
- Preferably, the second layer of the corrosion protective composition comprising at least one polyisobutene, filler and anti-oxidant is provided with a third layer, said third layer being a film comprising an olefinic polymer or copolymer. Alternatively, the first layer may be provided with a top layer formed by a wrapping tape, said wrapping tape comprising a first layer comprising the film comprising the olefinic polymer or copolymer and a second layer comprising the composition comprising at least one polyisobutene, filler and anti-oxidant and having a total thickness of about 1.0 to about 3.0 cm, more preferably about 1.2 to about 2.8 cm. However, it is also within the scope of this invention that the second layer of the composition comprising at least one polyisobutene, filler and anti-oxidant is enclosed by a shrink sleeve or wrap-around sleeve or sheet which are well known in the art.
- According to another preferred embodiment of the invention, extended tubular articles or sections thereof, e.g. a pipe or a pipe line or a section thereof, that are connected to each other by connecting means or structures such as joints and flanges, wherein these connecting means or structures and the extended tubular articles do not have a gradual transition, a non-hardening composition consisting essentially of the polyisobutene and the filler material described above is preferably used to create a gradual transition. The advantage of applying such a non-hardening composition is that the combination of the corrosive protecting composition described above and the third layer, e.g. the film or the wrapping tape, can more easily be wrapped around the transition of extended tubular article and connecting means or structure. This non-hardening composition contains essentially about 90-99% by weight of the polyisobutene and 1-10% by weight of the filler material. This non-hardening composition may be applied below to the first layer of the adhesive composition, between said first layer of the adhesive composition and the second layer of the corrosive protective composition or between said second layer of the corrosive protective composition and the third layer of the corrosion protecting layer disclosed below.
- According to a preferred embodiment of the present invention, the corrosion protecting layer which is applied to the surface of the adhesive composition comprises a polyolefin material, preferably a homopolymer or a copolymer of an optionally substituted, linear or branched C2-C12 alkene. In addition, it is preferred that the corrosion protecting layer according to this invention is heat shrinkable. More preferably, this corrosion protecting layer comprises a shrink sleeve or a wrap-around sleeve or sheet as is disclosed above.
- According to another preferred embodiment of the present invention, the corrosion protecting layer comprises the composition disclosed above which comprises a polyisobutene having a glass transition temperature of less than −20° C. and surface tension of less than 40 mM/m at a temperature above the glass transition temperature of said polyisobutene; a filler material; and an anti-oxidant, wherein said anti-oxidant is selected from the group consisting of a primary and a secondary anti-oxidant.
- Accordingly, the adhesive composition according to the present invention is in particular useful in the following methods for providing corrosion protection.
- A high shear adhesive tape comprising a backing material may carry on the surface thereof a layer of the adhesive composition according to the present invention, wherein the backing material comprises an impact resistant polymeric material that is preferably made of a polyolefin. The high shear adhesive tape can be wound around an extended tubular article or a part thereof, e.g. a welded joint. The backing material of the high shear adhesive tape preferably comprises an impact resistant polymeric material. The high shear adhesive tape has preferably a totals thickness of 5-30 mils.
- Another application concern pipes or pipelines provided with a propylene covering. For example, a layer of the adhesive composition according to the present invention may be applied to (a part of) the propylene covering to bond a second covering, in particular where heat shrinkable sleeves are to be provided onto such propylene coverings as is disclosed in e.g. CA A 2.308.802.
- Likewise, the adhesive composition according to the present invention may be used in a method for forming a composite sleeve having heat shrinkable end portions, wherein an inner covering member is disposed on a mandrel and a sleeve is disposed around the inner member and the mandrel, wherein the sleeve extends beyond both ends of the inner member. The sleeve is manufactured from a heat shrinkable sheet having end portions which are to be bonded together at an overlapping portion. Subsequently, the sleeve is heat shrunk so that the sleeve is bonded to the inner member to form the composite sleeve. Additionally, where a sleeve is used to connect two pre-insulated pipe sections, the adhesive composition according to the present invention may be applied to the edges of the insulation and/or to the edges of the sleeve to ensure not only a good bond between the two, but also a water tight seal.
- Furthermore, the adhesive composition according to the present invention may be used to apply a closure comprising a heat resistant backing layer, wherein to a surface of the backing layer a layer of the adhesive composition is applied, to a heat shrinkable wrap around sleeve. The closure is applied to the overlapping sections of the wrap around sleeve prior to heat shrinking to prevent slippage of the overlapping sections during heat shrinking and to prevent subsequent creeping of the overlap joint.
- The adhesive composition according to the present invention may also be used to improve the bonding between epoxy base layers provided on pipes and pipelines and outer coatings, e.g. marine concrete.
- The adhesive composition according to the present invention may also comprise a filler material, which is preferably an active reinforcing filler, preferably a fumed silica, e.g. AEROSIL® available from Degussa. According to this embodiment, the adhesive composition comprises about 1 to about 10 percent by weight of the filler material, based on the total weight of the adhesive composition. An advantage of using a fumed silica is that the adhesive composition keeps its translucency thereby enabling visible inspection of the surface of the extended tubular article after application of the adhesive composition.
Claims (25)
1-21. (canceled)
22. A process for providing an article or section thereof with a corrosion protecting system, the process comprising:
(a) applying a layer of an adhesive composition to a surface of the article or section thereof, and, subsequently,
(b) applying a corrosion protecting layer to the layer of the adhesive composition, wherein the adhesive composition comprises a polyolefin blend comprising 30% to 100% by weight of a polyisobutene and 0% to 70% by weight of an olefin polymer, based on the total weight of the polyolefin blend, said polyisobutene having:
(i) a glass transition temperature of lower than −40° C.; and
(ii) a number average molecular weight Mn of 1,300 to 1,000,000.
23. The process according to claim 22 , wherein the polyisobutene has a surface tension of less than 40 mN/m at 20° C.
24. The process according to claim 22 , wherein the olefin polymer has a glass transition temperature of less than −20° C.
25. The process according to claim 24 , wherein the olefin polymer is selected from the group consisting of:
(a) a polymer comprising 50.0% to 99.9% by weight of isobutene and 0.1% to 50.0% of an optionally substituted, linear or branched C2-C12 alkene or an optionally substituted, linear or branched C2-C12 alkadiene, based on the total weight of the polymer;
(b) a polymer comprising 50.0% to 99.9% by weight of propene and 0.1% to 50.0% of a an optionally substituted, linear or branched C2-C12 alkene, based on the total weight of the polymer;
(c) a polymer comprising 0.1% to 50.0% by weight of ethene and 50.0% to 99.9% of an optionally substituted, linear or branched C2-C12 alkene, based on the total weight of the polymer; and
(d) a polymer comprising 0.1% to 50.0% by weight of 2-methyl-1-pentene and 50.0% to 99.9% of an optionally substituted, linear or branched C2-C12 alkene, based on the total weight of the polymer, and mixtures thereof.
26. The process according to claim 24 , wherein the olefin polymer is not crosslinked.
27. The process according to claim 22 , wherein the article is a tubular article
28. The process according to claim 27 , wherein the tubular article is a pipe or a pipe line.
29. The process according to claim 22 , wherein the article comprises steel, concrete, or both.
30. The process according to claim 22 , wherein the article is pre-coated.
31. The process according to claim 30 , wherein the pre-coat comprises an expoxy resin.
32. The process according to claim 28 , wherein the pipe or pipe line is pre-coated.
33. The process according to claim 32 , wherein the pre-coat comprises an expoxy resin.
34. The process according to claim 22 , wherein the article is provided with a base layer.
35. The process according to claim 34 , wherein the base layer comprises a homopolymer or a copolymer of an optionally substituted, linear or branched C2-C12 alkene.
36. The process according to claim 28 , wherein the pipe or pipe line is provided with a base layer.
37. The process according to claim 35 , wherein the base layer comprises a homopolymer or a copolymer of an optionally substituted, linear or branched C2-C12 alkene.
38. The process according to claim 22 , wherein the corrosion protecting layer comprises a homopolymer or a copolymer of an optionally substituted, linear or branched C2-C12 alkene.
39. The process according to claim 22 , wherein the corrosion protecting layer is heat shrinkable.
40. The process according to claim 39 , wherein the corrosion protecting layer comprises a shrink sleeve.
41. The process according to claim 22 , wherein the corrosion protecting layer comprises a polyisobutene having a glass transition temperature of less than −20° C. and a surface tension of less than 40 mN/m at 20° C. and a filler material.
42. The process according to claim 22 , wherein the corrosion protecting layer comprises a tape.
43. The process according to claim 25 , wherein the optionally substituted, linear or branched C2-C12 alkene and the optionally substituted, linear or branched C2-C12 alkadiene are substituted with one or more halogen atoms.
44. The process according to claim 25 , wherein the optionally substituted, linear or branched C2-C12 alkene is selected from the group consisting of ethene, 1-propene, 2-methyl-1-propene, 1-butene, 2-butene, 1-pentene, 2-methyl-1-pentene, 1-hexene and 1-octene.
45. The process according to claim 25 , wherein the optionally substituted, linear or branched C2-C12 alkadiene is selected from the group consisting of butadiene, isoprene, halogenated butadiene, halogenated isoprene, styrene and halogenated styrene.
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US20110123791A1 (en) * | 2003-07-14 | 2011-05-26 | Frans Nooren Afdichtingssystemen B.V. | Composition for the protection of a shaped article against corrosion |
US8105963B2 (en) | 2003-07-14 | 2012-01-31 | Frans Nooren Afdichtingssystemen B.V. | Composition for the protection of a shaped article against corrosion |
US9297490B2 (en) | 2006-11-08 | 2016-03-29 | Frans Nooren Afdichtingssystemen B.V. | Process for providing an extended tubular article with a corrosion protection coating system having self-repairing properties |
US9926630B2 (en) | 2012-07-13 | 2018-03-27 | Frans Nooren Afdichtingssystemen B.V. | Process for the protection against corrosion of an article in a wet environment and composition therefore |
US10801114B2 (en) | 2012-07-13 | 2020-10-13 | Frans Nooren Afdichtingssystemen B.V. | Process for the protection against corrosion of an article in a wet environment and composition therefore |
JP2015192109A (en) * | 2014-03-28 | 2015-11-02 | 富士フイルム株式会社 | Backside protective sheet for solar batteries and solar battery module |
WO2016028148A1 (en) | 2014-08-22 | 2016-02-25 | Frans Nooren Afdichtingssystemen B.V. | Composition for the protection of an article against corrosion |
US11060386B2 (en) | 2018-11-01 | 2021-07-13 | Pro-Pipe Service & Sales Ltd. | Tubular for downhole use |
US11619121B2 (en) | 2018-11-01 | 2023-04-04 | Pro-Pipe Service & Sales Ltd. | Method for forming a sleeve for insulating a joint of downhole tubing |
US20220064561A1 (en) * | 2019-01-07 | 2022-03-03 | Nippon Steel Corporation | Composition, and threaded connection for pipes including lubricant coating layer formed from the composition |
Also Published As
Publication number | Publication date |
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WO2008056979A3 (en) | 2008-10-02 |
EP2081761A2 (en) | 2009-07-29 |
DK2081761T3 (en) | 2010-06-07 |
ES2342338T3 (en) | 2010-07-05 |
CA2669277A1 (en) | 2008-05-15 |
CA2669277C (en) | 2014-10-28 |
EP4209337A1 (en) | 2023-07-12 |
AU2007318317A1 (en) | 2008-05-15 |
EP2210734A3 (en) | 2010-11-17 |
AU2007318317A2 (en) | 2009-07-16 |
EP3147118A1 (en) | 2017-03-29 |
DE602007005273D1 (en) | 2010-04-22 |
US9297490B2 (en) | 2016-03-29 |
AU2007318317B2 (en) | 2011-10-27 |
ATE460269T1 (en) | 2010-03-15 |
EP2081761B1 (en) | 2010-03-10 |
RU2011140832A (en) | 2013-04-20 |
EP3147118B1 (en) | 2023-01-18 |
WO2008056979A2 (en) | 2008-05-15 |
PL2081761T3 (en) | 2010-08-31 |
US20140318686A1 (en) | 2014-10-30 |
SI2081761T1 (en) | 2010-06-30 |
EP2210734A2 (en) | 2010-07-28 |
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