METHODS FOR PRODUCING CORROSION RESISTING PARTICLES AND METHODS FOR PRODUCING COATING COMPOSITIONS THAT INCLUDE SUCH PARTICLES

• US 20070149682A1
• Filed: 12/13/2006
• Published: 06/28/2007
• Est. Priority Date: 08/26/2005
• Status: Abandoned Application

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Ragunathan, Kaliappa
• Application Number:
  US11/610,034
• Publication Number:
  US 20070149682A1
• Time in Patent Office: Days
• US Class Current: 524/442
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/32 Phosphorus-containing compounds
• CPC Class Codes: C08K 3/34 Silicon-containing compounds
• CPC Class Codes: C08K 3/38 Boron-containing compounds
• CPC Class Codes: C09D 5/084 Inorganic compounds
• CPC Class Codes: C09D 7/48 Stabilisers against degradation by oxygen, light or heat
• CPC Class Codes: C09D 7/67 Particle size smaller than 100 nm
• CPC Class Codes: C09D 7/68 Particle size between 100-1000 nm
• CPC Class Codes: Y10S 977/778 within specified host or matrix material, e.g. nanocomposite films
• CPC Class Codes: Y10S 977/779 Possessing nanosized particles, powders, flakes, or clusters other than simple atomic impurity doping
• CPC Class Codes: Y10T 428/256 Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/258 Alkali metal or alkaline earth metal or compound thereof
• CPC Class Codes: Y10T 428/259 Silicic material
• CPC Class Codes: Y10T 428/2991 Coated
• CPC Class Codes: Y10T 428/31522 Next to metal
• CPC Class Codes: Y10T 428/31529 Next to metal
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers

Abstract

Coating compositions are disclosed that include corrosion resisting particles such that the coating composition can exhibit corrosion resistance properties. Also disclosed are substrates at least partially coated with a coating deposited from such a composition and multi-component composite coatings, wherein at least one coating later is deposited from such a coating composition. Methods and apparatus for making corrosion resisting particles are also disclosed.

Claims

1. A method for producing particles comprising an inorganic oxide network comprising silicon and an inorganic material different from silicon, comprising:

(a) combining a metal salt with water to produce a solution comprising a hydrolyzed species comprising a polyvalent metal ion; and

then (b) reacting the hydrolyzed species with a silicon compound.

2. The method of claim 1, wherein metal salt comprises Ce³⁺, Ce⁴⁺, Zn²⁺, Zn⁴⁺, Mg²⁺, Y³⁺, Ca²⁺, Mn⁷⁺, or Mo⁶⁺.

3. The method of claim 1, wherein the inorganic oxide network comprises zinc, cerium, yttrium, zirconium, manganese, magnesium, or calcium in combination with silicon, phosphorous, and/or boron.

4. The method of claim 3, wherein the inorganic oxide network comprises silicon and cerium, zinc, zirconium, and/or manganese.

5. The method of claim 1, wherein silicon compound comprises an organosilane.

6. The method of claim 5, wherein the organosilane comprises tetramethoxysilane, tetraethoxysilane, tetra-n-propoxysilane, tetra-n-butoxysilane, methyltrimethoxysilane, methyltriethoxysilane, or a mixture thereof.

7. The method of claim 5, wherein the organosilane is dissolved in a water soluble organic solvent prior to its combination with a metal salt and water.

8. The method of claim 1, wherein the method does not include the use of sulfuric acid.

9. The method of claim 1, further comprising adding a base to the solution.

10. A method for making a coating composition comprising:

(a) producing particles comprising an inorganic oxide network comprising silicon and an inorganic material different from silicon according to the method of claim 1;

and then

(b) adding the particles to a composition comprising a film-forming resin.

18. The method of claim 1, further comprising adding a base.

11. A method for producing particles comprising an inorganic oxide network comprising silicon and an inorganic material different from silicon, comprising simultaneously adding to water reactants comprising:

(a) a metal salt, and (b) an organosilane.

12. The method of claim 11, wherein metal salt comprises Ce³⁺, Ce⁴⁺, Zn²⁺, Zn⁴⁺, Mg²⁺, Y³⁺, Ca²⁺, Mn⁷⁺, or Mo⁶⁺.

13. The method of claim 11, wherein the inorganic oxide network comprises zinc, cerium, yttrium, zirconium, manganese, magnesium, or calcium in combination with silicon, phosphorous, and/or boron.

14. The method of claim 13, wherein the inorganic oxide network comprises silicon and cerium, zinc, zirconium, and/or manganese.

15. The method of claim 11, wherein the organosilane comprises tetramethoxysilane, tetraethoxysilane, tetra-n-propoxysilane, tetra-n-butoxysilane, or a mixture thereof.

16. The method of claim 15, wherein the organosilane is dissolved in a water soluble organic solvent prior to its combination with a metal salt and water.

17. The method of claim 11, wherein the method does not include the use of sulfuric acid.

19. A method for making a coating composition comprising:

(a) producing particles comprising an inorganic oxide network comprising silicon and an inorganic material different from silicon according to the method of claim 11;

and then

(b) adding the particles to a composition comprising a film-forming resin.