Abstract: Coatings containing particulate metal alloy are disclosed. The coatings provide corrosion protection to a substrate, such as a metal substrate. The coatings contain zinc-metal-containing alloy in flake form, most particularly an alloy flake of zinc and aluminum. The coating can be from compositions that are water-based or solvent-based. The compositions for providing the coating may also contain a substituent such as a water-reducible organofunctional silane, or a hexavalent-chromium-providing substance, or a titanate polymer, or a silica substance constituent. The coating may desirably be topcoated.

Abstract: The present invention provides metal surface treatment agents and metal surface treatment methods which can form a high anticorrosion coating without use of hexavalent chromium compounds which are a cause of environmental pollution. In the present invention, a metal surface is coated with a metal surface treatment agent made of a composition containing a compound containing at least one or more mercapto groups per molecule and, depending upon need, a curing agent, curing catalyst and/or silica and the coating of the metal surface treatment agent is heat-treated.

Abstract: A ceramic fiber insulation material is disclosed. It is prepared from a precursor blend generally comprising a gelled colloid and a ceramic fiber filler. Other filler, e.g., other fiber of refractory material, is contemplated, particularly when mixed with ceramic fiber. The gelled colloid ban be formed such as by mixing a gelling agent with a colloid of inorganic oxide or by blending anionic colloid with cationic colloid. The gelling agent is typically nonionic and water-soluble. The blend is trowelable, pumpable and possesses excellent adhesive characteristics including the ability to stick to -most surfaces, including metal surfaces. The blend is also virtually shrink-free during drying and, after drying, can provide the insulation material.

Abstract: There is disclosed a water-reducible, chrome-free coating composition for providing corrosion protection to a substrate, such as a metal substrate. The deposited coating film is corrosion-resistant and, for coated articles which are threaded, e.g., steel fasteners, the coating provides a non-thread-filling coating. The coating composition contains particulate metal, such as particulate zinc or aluminum. Although substituents can be separately packaged, the composition is virtually always a one-package coating composition. The composition is water-based, while also containing low-boiling organic liquid. The composition also contains water-reducible organofunctional silane, particularly an epoxy functional silane, as a binding agent. The composition has highly desirable, extended shelf life. The composition can be easily applied in usual manner, such as dip-drain or dip-spin technique, and readily cures at elevated temperature.

Abstract: A method of preparing electrodes is now described, which electrodes have enhanced adhesion of subsequently applied coatings combined with excellent coating service life. In the method, a substrate metal, such as a valve metal as represented by titanium, is provided with a highly desirable rough surface characteristic for subsequent coating application. This can be achieved by various operations including etching to ensure a roughened surface morphology. In subsequent operations, a barrier layer is provided on the surface of enhanced morphology. This may be achieved by operations including heating, as well as including thermal decomposition of a layer precursor. Subsequent coatings provide enhanced lifetime even in the most rugged commercial environments.

Abstract: An apertured and porous metal article can find use, for example, in diaphragm or membrane electrolysis cells. The article may comprise a thin and flexible metal foam of small pores which, typically, has been perforated with large apertures. The article may also be provided with an electrocatalytic coating. It can be in substantial physical contact with a membrane or diaphragm separator used in the cell for separating anode and cathode members or compartments. There is also disclosed the preparation of the article and an electrolysis cell utilizing the resulting apertured and porous metal article.

Abstract: A ceramic fiber insulation material is disclosed. It is prepared from a precursor blend generally comprising a gelled colloid and a ceramic fiber filler. Other filler, e.g., other fiber of refractory material, is contemplated, particularly when mixed with ceramic fiber. The gelled colloid ban be formed such as by mixing a gelling agent with a colloid of inorganic oxide or by blending anionic colloid with cationic colloid. The gelling agent is typically nonionic and water-soluble. The blend is trowelable, pumpable and possesses excellent adhesive characteristics including the ability to stick to most surfaces, including metal surfaces. The blend is also virtually shrink-free during drying and, after drying, can provide the insulation material.

Abstract: A method is now disclosed for the making of compressed refractory fiber shapes, e.g., compressed ceramic fiber shapes, having a textured surface and an aggregate body. The shapes can be obtained by molding and therefore may be simple or complex. For the process, small discrete fragments of refractory fiber in accumulated form are suspended in a colloidal dispersion, such as the colloidal dispersion provided by colloidal silica. Colloidal mixtures, as of colloidal silica with colloidal alumina are also most serviceable. The fragments and the dispersion are mildly mixed so as not to thoroughly disperse the fiber fragments, but rather to form globules of the fiber in the resulting blend. The resulting material is shaped, e.g., molded under pressure, and usually dried while under pressure, which drying can be at elevated temperature.

Abstract: An electrode is disclosed having a coating on part of the electrode, e.g., a front face, comprising the oxides of tin, antimony, at least one platinum group metal and at least one valve metal. Another part of the electrode, such as a back face, has a coating comprising the oxides of at least one valve metal and at least one platinum group metal. The electrode can be generally plate-shaped and most desirably has at least one chamfered corner. The electrode is particularly useful in a cell wherein brine electrolyte is electrolyzed to prepare a disinfectant solution containing hypochlorite. The disinfectant solution can be especially serviceable, such as in maritime application, for treating water, e.g., freshwater as represented by desalinated water.

Abstract: An insulating roller cover is now disclosed that provides a highly desirable combination of features. The cover is free from asbestos and is therefore of more desirable construction for handling and use. For the roller cover, at least substantially ceramic fiber is highly compressed, providing a dense and refractory, elevated temperature resistant insulating cover. The cover may itself serve as a load bearing surface; or may provide a foundation or protective media for annular discs or 10 sleeve members made of various, load bearing materials. These load bearing materials may be unable to resist direct contact with the shaft due to thermal shock or the differences in their respective expansion and contraction rates. Where impregnant is utilized with the highly compressed fiber, such will often comprise a colloidal substituent.

Abstract: An electrode, electrochemical cell, and electrochemical processes are disclosed. The electrode is a porous, multi-layered electrode which can have an element in flexible, strip form wound around a central, usually flat plate core, which core may serve as a current distributor. In any form, each layer can be represented by a very thin, highly flexible metal mesh. This can be a fine, as opposed to a coarse, mesh which has extremely thin strands and small voids. The electrode will have an active coating. For utilizing this electrode, the cell in one form will be a monopolar cell providing upward, parallel electrolyte flow through the porous, multi-layered electrode. A representative cell can have such electrode at least substantially filling an electrode chamber. The cells can be contained in a cell box that will provide the desired flow-through relationship for the electrolyte to the electrode.

Abstract: A method of protecting reinforced concrete structures comprising of applying a protective cathodic coating containing a non-corroding metal and an electrochemically active material on concrete wherein the protective coating is formed by thermally spraying a mixture of said non-corroding metal such as a valve metal and said electrochemically active material. The coating may also be formed by applying a precursor of the electrochemically active material and a metal-containing layer to concrete, then anodically polarizing said metal layer to convert the precursor into an electrochemically active material.

Abstract: There is disclosed a cell sealing mean particularly for a chlor-alkali diaphragm cell. The sealing means will usually be contained along a rim portion at the outer edge of an electrode assembly of the diaphragm cell. The sealing means comprises a pneumatic gasket system. In one embodiment, the system can have an outer gasket member comprising a solid and thick, elongated elastomeric strip element. The strip element will generally have front and back major faces, with the front face containing a channel, and with a side face typically having a flange. Combined with the outer gasket member in this embodiment is an inner gasket member that is a thin, elongated elastomeric strip member. It has an inflatable hollow and flexible tube element forming at least a portion of the inner gasket member. It is desirable that the element be a laminate of differing laminate materials.

Abstract: A metal coating of typically a valve metal, especially a titanium metal coating, is applied by thermal spraying to the surface of concrete, most particularly steel-reinforced concrete. The metal such as titanium may be sprayed by any one of several thermal spraying techniques including flame spray, electric-arc spray, plasma spray, high-velocity oxyfuel spray, or detonation gun spray. The metal coating should be tightly adhered to the concrete and desirably will have a porosity to facilitate extensive coating of the metal itself, as well as facilitate any activation that may be needed for the metal. Such activation can be in the form of an electrochemically active material which allows the coating to function in electrochemically active form. One coating option is to apply a solution onto the spray-applied metal, then polarize the metal anodically to effect deposition of active material on the metal.

Abstract: There is disclosed a water-reducible, chromium-free coating composition for providing corrosion protection to a substrate, such as a metal substrate. The deposited coating film is corrosion-resistant and for coated articles which are threaded, e.g., steel fasteners, the coating provides a non-thread-filling coating. The coating composition contains particulate metal, such as particulate zinc or aluminum. Although substituents can be separately packaged, the composition is virtually always a one-package coating composition. The composition contains water-reducible organofunctional silane, particularly an epoxy functional silane, as a binding agent. The composition has highly desirable, extended shelf life. The composition can be easily applied in the usual manner, such as dip-drain or dip-spin technique, and readily cures at elevated temperature.

Abstract: A method is now disclosed for the making of compressed refractory fiber shapes, e.g., compressed ceramic fiber shapes, having a textured surface and an aggregate body. The shapes can be obtained by molding and therefore may be simple or complex. For the process, small discrete fragments of refractory fiber in accumulated form are suspended in a colloidal dispersion, such as the colloidal dispersion provided by colloidal silica. Colloidal mixtures, as of colloidal silica with colloidal alumina are also most serviceable. The fragments and the dispersion are mildly mixed so as not to thoroughly disperse the fiber fragments, but rather to form globules of the fiber in the resulting blend. The resulting material is shaped, e.g., molded under pressure, and usually dried while under pressure, which drying can be at elevated temperature.

Abstract: A cell, particularly a membrane cell, that will generally be oriented in an at least substantially vertical positioning, is provided with an array of blade electrodes. The blade electrodes are Delta shape in cross-section, having a flat back face and forwardly sloping sides meeting at a forward edge. Such electrodes can be secured to a current distributor bar, typically on a flat front face of the bar. The forward edge of an electrode blade may be placed opposite a counter electrode of the same or different structure, with a membrane separator usually interposed therebetween. Electrical connection can be made to the electrode blades from the distributor bar, and to the distributor bar through boss electrical connectors. Baffles, which may also be secured to the distributor bar, help establish a front chamber, containing the electrode blades, in front of the baffles, and a back chamber behind the baffles. Electrolyte circulates through the front chamber and recirculates through the back chamber.

Abstract: Methods, and various apparatus therefor, are disclosed for the electrolytic treatment of an acidic solution. Generally the method comprises: (a) providing an electrolytic cell, the cell comprising: (i) an anode chamber and an anode therein; (ii) a cathode chamber and a cathode therein; and (iii) a diaphragm. Usually the diaphragm is of a non-isotropic fibrous mat comprising 5-70 weight percent organic halocarbon polymer fiber in adherent combination with about 30-95 weight percent of finely divided inorganic particulate impacted into said fiber during fiber formation, the diaphragm having a weight per unit of surface area of about 3-12 kilograms per square meter. The method can continue by (b) introducing the acidic solution into the cell; (c) impressing a current on the anode and the cathode causing the migration of ions through the diaphragm; and (d) recovering a product of the electrolytic treatment from the anode chamber, or the cathode chamber, or from both chambers.

Abstract: An electrode, electrochemical cell, and electrochemical processes are disclosed. The electrode is a porous, multi-layered electrode which can have an element in flexible, strip form wound around a central, usually flat plate core, which core may serve as a current distributor. In any form, each layer can be represented by a very thin, highly flexible metal mesh. This can be a fine, as opposed to a coarse, mesh which has extremely thin strands and small voids. The electrode will have an active coating. For utilizing this electrode, the cell in one form will be a monopolar cell providing upward, parallel electrolyte flow through the porous, multi-layered electrode. A representative cell can have such electrode at least substantially filling an electrode chamber. The cells can be contained in a cell box that will provide the desired flow-through relationship for the electrolyte to the electrode.

Abstract: A process is disclosed, as well as apparatus useful therefor, for continuously electroplating a strip of reticulated foam using multiple electroplating zones that each contain electroplating bath. In each zone there is a cathode and an anode. In at least one electroplating zone there is an insoluble anode, typically as the sole anode. In some of the electroplating zones soluble anodes may be used. As a first cathode, there can be provided a cathode roll outside of the electroplating bath. The reticulated foam is guided in the bath past the anodes, as well as past cathodes, e.g., including a cathode roll which may be positioned outside of the bath. The resulting electroplated foam emerging from the bath has an improved electroplate weight distribution and the process achieves enhanced efficiencies and economies of operation.