Building material coating

• US 5,429,882 A
• Filed: 06/15/1994
• Issued: 07/04/1995
• Est. Priority Date: 04/05/1993
• Status: Expired due to Term

• Current Assignee: Revere Copper Products, Inc.
• Original Assignee: The Louis Berkman Company
• Inventors: Zamanzadeh, Mehrooz, Carey, Jay F. II
• Primary Examiner(s): ZIMMERMAN, JOHN J
• Application Number:
  US08/260,333
• Time in Patent Office: 384 Days
• Field of Search: 428/659, 428/685, 428/658, 428/935, 428/939, 428/646, 428/647, 428/648, 428/650, 428/674, 428/679, 148/242, 427/433
• US Class Current: 428/647
• CPC Class Codes: C22C 1/11 Making amorphous alloys
• CPC Class Codes: C23C 2/024 by cleaning or etching
• CPC Class Codes: C23C 2/08 Tin or alloys based thereon
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: E04D 3/30 of metal
• CPC Class Codes: E04F 13/12 of metal or with an outer layer of metal or enameled metal E04F13/0864 takes precedence
• CPC Class Codes: Y10S 428/939 Molten or fused coating
• CPC Class Codes: Y10T 428/12715 Next to Group IB metal-base component
• CPC Class Codes: Y10T 428/12722 Next to Group VIII metal-base component
• CPC Class Codes: Y10T 428/12792 Zn-base component
• CPC Class Codes: Y10T 428/12799 Next to Fe-base component [e.g., galvanized]

Abstract

A corrosion-resistant colored architectural material which is essentially lead free and is not highly reflective. The coating on the material is a two-phase metallic coating comprised of a large weight percentage of zinc and a relatively large weight percentage of tin. The tin-zinc coating may also include nickel and copper. The tin-zinc composition provides for both a highly corrosive-resistant coating which protects the surface of the architectural material from oxidation and also produces a gray, earth tone colored which is not highly reflective.

Claims

1. A coated metal material coated with a low-reflecting, highly corrosive-resistant, two-phase tin-zinc metallic alloy coating, said coating comprising at least 0.3 weight percent nickel, at least 0.05 weight percent metallic stabilizer selected from the group consisting of antimony and bismuth, at least 15 weight percent tin and at least 30 weight percent zinc wherein said tin content plus said zinc content exceeds 80 weight percent of said coating.

2. A coated metal material as defined in claim 1, wherein said nickel content is 0.3-0.9 weight percent.

3. A coated metal material as defined in claim 2, wherein said nickel content is 0.7 weight percent.

4. A coated metal material as defined in claim 1, wherein said zinc is 30-65 percent by weight.

5. A coated metal material as defined in claim 4, wherein said zinc content is 40-60 weight percent.

6. A coated metal material as defined in claim 1, wherein said coating includes lead in an amount less than 0.01 percent by weight.

7. A coated metal material as in claim 1, wherein said metal coating comprises:

space="preserve" listing-type="tabular">______________________________________ Tin 15.0-70.0% Zinc 30.0-85.0% Bismuth 0.0-1.7% Antimony 0.0-7.5% Copper 0.0-5.0% Iron 0.0-0.1% Lead 0.0-0.05% Nickel 0.3-5.0% ______________________________________

8. A coated metal material as defined in claim 1, wherein said metal material is carbon steel.

9. A coated metal material as defined in claim 1, wherein said metal material is stainless steel.

10. A coated metal material as defined in claim 1, wherein said metal material is copper.

11. A coated metal material as defined in claim 1, wherein the surface of said metal material is plated with a thin nickel layer prior to applying said metallic coating.

12. A coated metal material as defined in claim 11, wherein said nickel layer thickness up to three microns.

13. A coated metal material as defined in claim 12, wherein said nickel layer is electroplated onto said metal material.

14. A coated metal material as defined in claim 1, wherein said tin content plus zinc content exceeds 90 weight percent.

15. A coated metal material as defined in claim 1, wherein said tin content plus zinc content exceeds 95 weight percent.

16. A coated metal material formed of a carbon steel or stainless steel sheet metal roofing material coated with a low-reflecting, highly corrosion-resistant, two phase, tin-zinc metallic coating, said sheet metal including a nickel barrier between said metallic coating and said steel sheet, said metal coating comprising tin, zinc, nickel and at least 0.05 weight percent metal stabilizer selected from the group consisting of antimony and bismuth such that the coating includes:

space="preserve" listing-type="tabular">______________________________________ Tin 15.0-70.0% Zinc 30.0-85.0% Bismuth 0.0-1.7% Antimony 0.0-7.5% Iron 0.0-0.1% Lead 0.0-0.05% Nickel 0.3-1.0% Copper 0.0-2.0% ______________________________________

17. A coated metal material as defined in claim 16, wherein said zinc content is 40-60 weight percent.

18. A coated metal material as defined in claim 16, wherein said zinc content is 45-55 weight percent.

19. A coated metal material as defined in claim 16, wherein the tin content plus zinc content exceeds 95 weight percent.

20. A coated metal material as defined in claim 16, wherein said lead content is less than 0.01 weight percent.

21. A coated metal material as defined in claim 16, wherein said nickel content is 0.3-0.9 weight percent.

22. A coated metal material as defined in claim 21, wherein said nickel content is 0.7 weight percent.

23. A coated metal material as defined in claim 16, wherein the metal content of said material, excluding tin, zinc and nickel, is not more than 2.0 weight percent.

24. A coated metal material as defined in claim 23, wherein the metal content of said material, excluding tin, zinc and nickel, is not more than 1.0 weight percent.

25. A coated metal material as defined in claim 16, wherein said nickel barrier is up to 3 microns thick.

26. A coated metal material coated with a low-reflecting, highly corrosion-resistant, multiple phase tin-zinc metallic coating, said coating comprising of at least about 0.1 weight percent copper, at least 15 weight percent tin wherein said tin content plus the zinc content exceeds 80 weight percent of said coating.

27. A coated metal material as defined in claim 26, wherein said coating includes nickel.

28. A coated metal material as defined in claim 27, wherein said nickel content is 0.3-5.0 weight percent of said coating.

29. A coated metal material as defined in claim 28, wherein said metal coating comprises:

space="preserve" listing-type="tabular">______________________________________ Tin 15.0-70.0% Zinc 30.0-85.0% Copper 0.1-5.0% Nickel 0.3-5.0% ______________________________________

30. A coated metal material as defined in claim 29, wherein said metal coating comprises:

space="preserve" listing-type="tabular">______________________________________ Tin 35.0-[75.0] 70.0% Zinc 30.0-65.0% Copper 0.1-2.0% Nickel [0.0] 0.3-1.0% ______________________________________

31. A coated metal material as defined in claim 30, wherein said metal coating comprises:

space="preserve" listing-type="tabular">______________________________________ Tin 35.0-70.0% Zinc 30.0-65.0% Copper 0.1-1.5% Nickel 0.3-0.9% ______________________________________

32. A coated metal material as defined in claim 26, wherein said copper content is about 0.1-5.0 weight percent of said coating.

33. A coated metal material as defined in claim 32, wherein said copper content is about 0.1-1.6 weight percent of said coating.

34. A coated metal material as defined in claim 33, wherein said copper content is about 1.0-1.5 weight percent of said coating.

35. A coated metal material as defined in claim 32, wherein said coating includes nickel an said nickel content is 0.3-5.0 weight percent of said coating.

36. A coated metal material coated with a low-reflecting, highly corrosive-resistent, two-phase tin-zinc metallic alloy by continuously passing said metal material through a bath of molten metal, said metallic alloy comprising zinc, at least 15 weight percent tin and at least 0.1 weight percent copper.

37. A coated metal material coated with a low reflecting, highly corrosive-resistent, two-phase tin-zinc metallic alloy by continuously passing said metal material through a bath of molten metal, said metallic alloy comprising zinc, nickel, at least 15 weight percent tin, and at least 0.05 weight percent metallic stabilizer selected from the group consisting of antimony, bismuth and copper.