# US 2017/0283306 A1 · Glass composite suitable for providing a protective coating on untreated substrates

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- Number: US 2017/0283306 A1
- Document ID: US20170283306A1
- Status: Published application
- Kind: A1
- Application number: 15/315,282
- Filed: 2015-05-12
- Published: 2017-10-05
- Earliest claimed: 2014-05-12
- Assignees: Prince Minerals, Inc.
- Applicants: Prince Minerals LLC
- Inventors: Christian Schlegel; Jon Davies; Mike Koenigstein
- Web page: https://patentgrep.com/patent/US20170283306A1

## CPC

- C03C 3/118: containing aluminium
- C03C 3/064: containing boron
- C03C 3/095: containing rare earths
- C03C 8/02: Frit compositions, i.e. in a powdered or comminuted form
- C03C 8/06: containing halogen
- C03C 8/08: containing phosphorus
- C03C 8/22: containing two or more distinct frits having different compositions
- C04B 20/1074: {Silicates, e.g. glass}
- C04B 28/02: containing hydraulic cements other than calcium sulfates
- C23D 5/04: by dry methods
- C03C 2207/04: for steel
- C04B 2111/26: Corrosion of reinforcement resistance
- C03C: CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C23D: ENAMELLING OF, OR APPLYING A VITREOUS LAYER TO, METALS

## Abstract

Glass composite coating systems herein may be used for industrial applications serving as a chemical barrier against substrate oxidation or other deterioration by corrosive agents, may prevent material build-up in process piping and equipment, may provide for improved bonding strength between concrete and reinforcing media, and may inhibit microbial build-up on exposed surfaces. Traditionally, glass coatings are emplaced on relatively pristine, pre-prepared surfaces. Glass composite coating systems described herein may be bonded to untreated substrates, without the need to clean, polish and/or pre-treat the substrate.

## Claims

### Claim 1

A process for emplacing a glass coating on a substrate, the process comprising:
applying a glass coating system to at least one surface of a non-treated substrate;
at least one of admixing a primary frit or powder with a secondary frit or powder to form the glass coating system, or applying a secondary frit or powder composition to a surface formed by the glass coating system after the applying step;
at least one of admixing a second secondary frit or powder or applying a second secondary frit or powder to a surface formed by the secondary frit or powder composition;
sintering the glass coating system to form a glass coating therefrom on the at least one surface of the substrates;
wherein the second secondary frit comprises from about 7 wt % to about 19 wt % P2O5.

### Claim 2

(canceled)

### Claim 3

(canceled)

### Claim 4

(canceled)

### Claim 5

(canceled)

### Claim 6 (depends on 1)

The process of claim 1, wherein the glass coating system is formed by admixing:
from about 5 wt % to about 21 wt % B2O3;
from about 1 wt % to about 7 wt % Li2O;
from about 4 wt % to about 22 wt % Na2O; and
from about 46 wt % to about 65 wt % SiO2.

### Claim 7 (depends on 6)

The process of claim 6, further comprising admixing at least one of CoO, MnO, NiO, CeO2, CuO and MoO3, wherein when used:
the CoO concentration is from about 0.2 wt % to about 5 wt %;
the MnO concentration is from about 0.2 wt % to about 6.5 wt %;
the NiO concentration is from about 0.05 wt % to about 5 wt %;
the CeO2 concentration is from about 0.1 wt % to about 3.5 wt %;
the CuO concentration is from about 0.1 wt % to about 3.5 wt %; and
the MoO3 concentration is from about 0.2 wt % to about 6 wt %.

### Claim 8 (depends on 6)

The process of claim 6, further comprising admixing at least one of Al2O3, CaO, ZrO2, Fe2O3 and ZnO, wherein when used:
the Al2O3 concentration is from about 0.1 wt % to about 3 wt %;
the CaO concentration is from about 0.5 wt % to about 8.5 wt %;
the ZrO2 concentration is from about 0.5 wt % to about 9 wt %;
the Fe2O3 concentration is from about 0.1 wt % to about 5.5 wt %; and
the ZnO concentration is from about 0.1 wt % to about 3 wt %.

### Claim 9 (depends on 6)

The process of claim 6, further comprising admixing at least one of F2 and V2O5, wherein when used:
the F2 concentration is from about 0.5 wt % to about 8.5 wt %; and
the V2O5 concentration is from about 0.1 wt % to about 5 wt %.

### Claim 10 (depends on 6)

The process of claim 6, further comprising admixing at least one of Sb2O3 and WO3, wherein when used:
the Sb2O3 concentration is from about 0.05 wt % to about 2 wt %; and
the WO3 concentration is from about 0.1 wt % to about 3.5 wt %.

### Claim 11 (depends on 6)

The process of claim 6, further comprising admixing at least one of BaO, K2O, and P2O5, wherein when used:
the BaO concentration is from about 0.5 wt % to about 5.5 wt %;
the K2O concentration is from about 0.2 wt % to about 5 wt %; and
the P2O5 concentration is from about 0.5 wt % to about 3.5 wt %.

### Claim 12

(canceled)

### Claim 13 (depends on 1)

The process of claim 1, wherein the glass coating comprises from about 15 wt % to about 35 wt % of the secondary frit.

### Claim 14

(canceled)

### Claim 15

(canceled)

### Claim 16

A glass composite or glass coating system comprising:
(1) from about 5 wt % to about 21 wt %, from about 6 wt % to about 16 wt %, or from about 7 wt % to about 13.5 wt % B2O3,
(2) from about 1 wt % to about 7 wt %, from about 4 wt % to about 7 wt %, from about 1 wt % to about 6.5 wt %, from about 2.5 wt % to about 6.5 wt %, from about 3.5 to about 6.5 wt %, from about 1.5 wt % to about 4 wt %, or from about 2 wt % to about 3.5 wt % Li2O,
(3) from about 4 wt % to about 22 wt %, from about 6 wt % to about 18 wt %, or from about 7.5 wt % to about 16 wt % Na2O and
(4) from about 46 wt % to about 65 wt %, from about 49 wt % to about 61 wt %, from about 54 wt % to about 61 wt %, or from about 52 wt % to about 58 wt % SiO2.

### Claim 17 (depends on 16)

The composition of claim 16 further comprising from about 3 wt % to about 9 wt %, from about 4.5 wt % to about 9 wt %, from about 3 wt % to about 6.5 wt %, or from about 3 wt % to about 6 wt % TiO2, wherein TiO2 provides acid resistance properties.

### Claim 18 (depends on 16)

The composition of claim 16, further comprising at least one compound capable of forming a bond with FeO, the compound selected from CoO, MnO, NiO, CeO2, CuO and MoO3, wherein when used:
(1) the CoO concentration is from about 0.2 wt % to about 5 wt %, from about 0.2 wt % to about 4 wt %, or from about 0.4 wt % to about 3 wt %,
(2) the MnO concentration is from about 0.2 wt % to about 6.5 wt %, from about 0.5 wt % to about 4.8 wt %, or from about 0.8 wt % to about 3.5 wt %,
(3) the NiO concentration is from about 0.05 wt % to about 5 wt %, from about 0.05 wt % to about 3.5 wt %, or from about 0.05 wt % to about 2.8 wt %,
(4) the CeO2 concentration is from about 0.1 wt % to about 3.5 wt %, from about 0.3 to about 3 wt %, or from about 0.5 wt % to about 2.8 wt %,
(5) the CuO concentration is from about 0.1 wt % to about 3.5 wt %, from about 0.3 to about 3 wt %, or from about 0.5 wt % to about 2.2 wt %, and
(6) the MoO3 concentration is from about 0.2 wt % to about 6 wt %, from about 0.2 wt % to about 5 wt %, from about 3 wt % to about 6 wt %, from about 0.5 wt % to about 4.5 wt %, or from about 0.5 wt % to about 4 wt %.

### Claim 19 (depends on 16)

The composition of claim 16, further comprising at least one compound providing resistance to water and/or alkali, the compound selected from Al2O3, CaO, ZrO2, Fe2O3 and ZnO, wherein when used:
(1) the Al2O3 concentration is from about 0.1 wt % to about 3 wt %, from about 0.5 wt % to about 3 wt %, from about 0.1 wt % to about 1.8 wt %, or from about 0.1 wt % to about 1 wt %,
(2) the CaO concentration is from about 0.5 wt % to about 8.5 wt %, from about 1.5 wt % to about 7 wt %, or from about 2 wt % to about 5 wt %,
(3) the ZrO2 concentration is from about 0.5 wt % to about 9 wt %, from about 2 wt % to about 9 wt %, from about 0.5 wt % to about 5.5 wt %, or from about 0.5 wt % to about 5 wt %,
(4) the Fe2O3 concentration is from about 0.1 wt % to about 5.5 wt %, or from about 0.6 wt % to about 4.2 wt %, and
(5) the ZnO concentration is from about 0.1 wt % to about 3 wt % or from about 0.5 wt % to about 2.2 wt %.

### Claim 20 (depends on 16)

The composition of claim 16, further comprising at least one wetting compound selected from F2 and V2O5, wherein when used (i) the F concentration is from about 0.5 wt % to about 8.5 wt %, from about 0.5 to about 6 wt % or from about 0.7 wt % to about 5 wt %, and (ii) the V2O5 concentration is from about 0.1 wt % to about 5 wt % or from about 2 wt % to about 5 wt %.

### Claim 21 (depends on 16)

The composition of claim 16, wherein the Ni concentration is less than about 1 wt %, less than about 0.5 wt %, less than about 0.1 wt %, or wherein the composition has an essential absence of Ni, and the composition further comprises from about 0.1 to about 5.5 wt % or from about 0.6 wt % to about 4.2 wt % Fe2O3.

### Claim 22 (depends on 16)

The composition of claim 16, further comprising a compound capable of enhancing a chemical bond with FeO, the compound selected from Sb2O3 and WO3 wherein (i) the Sb2O3 concentration is from about 0.05 wt % to about 2 wt %, from about 0.05 wt % to about 1.5 wt %, or from about 0.1 wt % to about 1 wt % and (ii) the WO3 concentration is from about 0.1 wt % to about 3.5 wt %, from about 0.1 wt % to about 3 wt %/o, or from about 0.5 wt % to about 2.8 wt %.

### Claim 23 (depends on 16)

The composition of claim 16, further comprising from about 0.5 wt % to about 5.5 wt %, from about 1 wt % to about 4.5 wt %, or from about 1.5 wt % to about 3.5 wt % BaO, wherein BaO is a Li2O wetting agent.

### Claim 24 (depends on 16)

The composition of claim 16, further comprising from about 0.2 wt % to about 5 wt %, from about 0.2 wt % to about 3 wt %, or from about 0.5 wt % to about 2.5 wt % K2O, wherein K2O is an alkali equilibrium stabilizer.

### Claim 25 (depends on 16)

The composition of claim 16, further comprising from about 0.5 wt % to about 3.5 wt %, from about 0.5 wt % to about 3 wt %, from about 0.5 wt % to about 2.5 wt %, or from about 7 to about 19 wt % P2O5.

### Claim 26

(canceled)

### Claim 27 (depends on 16)

The composition of claim 16, comprising:
(1) from about 5 wt % to about 21 wt % B2O3,
(2) from about 1 wt % to about 6 wt % Li2O,
(3) from about 4 wt % to about 22 wt % Na2O,
(4) from about 46 wt % to about 65 wt % SiO2,
(5) from about 1.2 wt % to about 5 wt % CoO,
(6) from about 2 wt % to about 6.5 wt % MnO,
(7) from about 1.2 wt % to about 4.5 wt % NiO,
(8) from about 0.5 wt % to about 1.2 wt % Sb2O3, and
(9) from about 0.5 wt % to about 3 wt % CeO2.

### Claim 28 (depends on 16)

The composition of claim 16, further comprising at least one compound providing a source of calcium, the composition comprising from about 15 wt % to about 30 wt % or from about 20 wt % to about 25 wt % of compounds providing a source of calcium.

### Claim 29

(canceled)

### Claim 30 (depends on 16)

The composition of claim 16, wherein the composition comprises from about 4 wt % to about 7 wt % Li2O and from about 3 wt % to about 6 wt % MoO3.

### Claim 31 (depends on 16)

The composition of claim 16, wherein the weight ratio of Li2O to SiO2 is from about 0.01:1 to about 0.2:1, from about 0.015:1 to about 0.15:1, from about 0.02:1 to about 0.08:1, or from about 0.03:1 to about 0.07:1.

### Claim 32 (depends on 16)

The composition of claim 16, where the composition is a primary frit or powder having an average particle size of from about 10μ to about 100μ.

### Claim 33 (depends on 16)

A glass composite composition formed from at least two frits or powders comprising a primary frit or powder and a first secondary frit or powder, wherein
(1) the primary flit or powder corresponds to the composition of claim 16, and
(2) the first secondary frit or powder has an average particle size of from about 10μ to about 100μ and comprises
(a) from about 37 wt % to about 48 wt % SiO2,
(b) from about 1.5 wt % to about 5 wt % MoO3,
(c) from about 3 wt % to about 11 wt % Li2O,
(d) from about 2 wt % to about 7 wt % F2,
(e) from about 4 wt % to about 8.5 wt % CaO, and
(f) from about 5 wt % to about 14 wt % B2O3, and
wherein the glass composite composition comprises from 15 wt % to about 35 wt % or from about 20 wt % to about 22 wt % of the first secondary frit or powder.

### Claim 34 (depends on 33)

The composition of claim 33 further comprising a second secondary fit or powder, the second secondary frit or powder comprising from about 7 wt % to about 19 wt % P2O5.

### Claim 35 (depends on 16)

A coated article comprising a ferrous or non-ferrous substrate and a glass composite formed from the composition according to claim 16 deposited on at least one surface of the substrate.

### Claim at position 36

-42. (canceled)

### Claim 43 (depends on 16)

A method for coating a ferrous or non-ferrous substrate with a glass composite, the method comprising (i) applying a composition of claim 16 to at least one surface of a ferrous or non-ferrous substrate, and (ii) sintering the frit composition to form the glass composite therefrom on the at least one surface of the substrate.

### Claim 44

(canceled)

### Claim 45

(canceled)