Multilayer, corrosion-resistant finish and method
First Claim
1. A black, chrome-free, multilayer, corrosion-resistant finish, the corrosion-resistant finish for application to a metal substrate, the corrosion-resistant finish comprising at least three layers, the three layers including:
- a zinc-iron substrate layer, the zinc-iron substrate layer being electroplated to a select substrate, the zinc-iron substrate layer being electroplated to the select substrate from a select, non-cyanide, alkaline-based electroplating process;
a phosphate crystal conversion layer, the phosphate crystal conversion layer being non-electrolytic and formed upon the zinc-iron substrate layer using an orthophosphoric acid bath, the zinc-iron substrate layer and the phosphate crystal conversion layer thus forming a zinc-iron-phosphate-crystal substrate; and
a select sealer coating layer, the select sealer coating layer being black in color and chrome-free, the select sealer coating layer coating the zinc-iron-phosphate-crystal substrate, the coated zinc-iron-phosphate-crystal substrate thus forming the multilayer, corrosion-resistant finish.
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Abstract
The present invention provides a black, chrome-free, multilayer corrosion protection finish designed to meet extended corrosion properties. This corrosion-resistant finish is engineered to meet a minimum of 500 salt spray testing hours to white corrosion, and 1500 salt spray testing hours to red corrosion when tested to ASTM B117 standards. It is also designed to comply with the European Union Directive on End of Life Vehicles. This multilayer system is designed for use on automotive body sheet steel, automotive underbody parts, automotive under-hood parts, and some automotive interior parts specifying a gloss requirement greater than 4. This chrome-free, multilayer finish is a combination of a zinc-iron electroplated substrate, a non-electrolytic phosphate crystal conversion layer using orthophosphoric acid, and a Xylan/Teflon fluorocarbon sealer coating to form a three layer total corrosion protection system.
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Citations
27 Claims
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1. A black, chrome-free, multilayer, corrosion-resistant finish, the corrosion-resistant finish for application to a metal substrate, the corrosion-resistant finish comprising at least three layers, the three layers including:
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a zinc-iron substrate layer, the zinc-iron substrate layer being electroplated to a select substrate, the zinc-iron substrate layer being electroplated to the select substrate from a select, non-cyanide, alkaline-based electroplating process;
a phosphate crystal conversion layer, the phosphate crystal conversion layer being non-electrolytic and formed upon the zinc-iron substrate layer using an orthophosphoric acid bath, the zinc-iron substrate layer and the phosphate crystal conversion layer thus forming a zinc-iron-phosphate-crystal substrate; and
a select sealer coating layer, the select sealer coating layer being black in color and chrome-free, the select sealer coating layer coating the zinc-iron-phosphate-crystal substrate, the coated zinc-iron-phosphate-crystal substrate thus forming the multilayer, corrosion-resistant finish. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A multilayer, corrosion-resistant finish, the corrosion-resistant finish comprising:
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a zinc-iron substrate layer, the zinc-iron substrate layer for electroplated attachment to the metal substrate, the zinc-iron substrate layer being formed from a select non-cyanide, alkaline-based electroplating process;
a phosphate crystal conversion layer, the phosphate crystal conversion layer being formed upon the zinc-iron substrate layer, the zinc-iron substrate layer and the phosphate crystal conversion layer thus forming a zinc-iron-phosphate-crystal substrate; and
a select sealer coating layer, the select sealer coating layer coating the zinc-iron-phosphate-crystal substrate, the coated zinc-iron-phosphate-crystal substrate thus forming the multilayer, corrosion-resistant finish. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18)
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19. A method of applying a multilayer, corrosion-resistant finish to a metal substrate, the method comprising the steps of:
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electroplating a zinc-iron substrate layer upon the metal substrate via a select non-cyanide, alkaline-based electroplating process thus forming a zinc-iron-enveloped substrate;
bathing the zinc-iron-enveloped substrate in an orthophosphoric acid bath, the orthophosphoric acid bath forming a phosphate crystal conversion layer upon the zinc-iron-enveloped substrate, the phosphate crystal conversion layer thus forming a zinc-iron-phosphate-crystal-enveloped substrate; and
coating the zinc-iron-phosphate-crystal-enveloped substrate with a select sealer coating layer. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27)
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Specification