Chromium-free, metal surface-treating composition and surface-treated metal sheet

• US 6,040,054 A
• Filed: 01/29/1997
• Issued: 03/21/2000
• Est. Priority Date: 02/01/1996
• Status: Expired due to Fees

• Current Assignee: Toyoda Gosei Company Limited (Toyota Motor Corporation)
• Original Assignee: Toyoda Gosei Company Limited (Toyota Motor Corporation)
• Inventors: Shimizu, Toshiyuki, Takahashi, Tomomi, Odashima, Hisao
• Primary Examiner(s): Chen, Vivian
• Application Number:
  US08/791,077
• Time in Patent Office: 1,147 Days
• Field of Search: 148/240, 148/243, 148/251, 148/253, 148/259, 106/14.12, 106/14.44, 106/14.05, 106/14.21, 428/457, 428/458, 428/469, 428/470, 428/471, 428/472, 428/472.3, 428/413, 428/416, 428/463
• US Class Current: 428/413
• CPC Class Codes: B05D 7/51 One specific pretreatment, e.g. phosphatation, chromatation, in combination with one specific coating pretreatment of metallic substrates C23C; pretreatment before coating in general B05D3/00
• CPC Class Codes: C09D 5/08 Anti-corrosive paints
• CPC Class Codes: C23C 22/74 for obtaining burned-in conversion coatings
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31522 Next to metal
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31681 Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31699 Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31797 Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31909 Next to second addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31928 Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A chromium-free composition for treating metal surface comprising (a) a hydroxyl group-containing organic resin, (b) a phosphoric acid and (c) at least one of ions and compounds of at least one metal selected from the group consisting of Cu, Co, Fe, Mn, Sn, V, Mg, Ba, Al, Ca, Sr, Nb, Y and Zn, and (d) at least one of colloids (sol) or powders of SiO₂, SnO₂, Fe₂ O₃, Fe₃ O₄, MgO, ZrO₂, Al₂ O₃ and Sb₂ O₅ ; as well as a metal sheet or metal article having thereon (i) a coating film of the chromium-free composition and optionally (ii) a coating film of a coating composition comprising an organic resin and if desired a colloid (sol) or a powder.

Claims

1. A chromium-free composition for treating the surface of metals, the composition comprising:

(a) a hydroxyl group-containing organic resin;

(b) a phosphoric acid; and

(c) a metal ion or metal compound capable of supplying ions in the composition, the metal being at least one metal selected from the group consisting of Cu, Co, Fe, Mn, Sn, V, Mg, Ba, Al, Ca, Sr, Nb, Y and Zn,

wherein the composition comprises from about 2 to about 50 parts by weight of the phosphoric acid by 100 parts by weight of the hydroxyl group-containing organic resin, and the composition further comprises at least one colloid, sol, or powder selected from the group consisting of SiO₂, Fe₂ O₃, Fe₃ O₄, MgO, ZrO₂, SnO₂, Al₂ O₃ and Sb₂ O₅ said composition being effective to provide corrosion resistance to a metal when applied to the surface of said metal in an amount to provide a coating weight of from about 0.1 g/m² to about 3.0 g/m² on dry basis.

2. The composition according to claim 1, wherein the composition, when applied to a Zn-plated steel sheet and dried, form a coating film which has an ability to remain unremoved from the steel sheet after immersion in boiling water for 30 minutes.

3. The composition according to claim 1, wherein the metal ion or metal compound as component (c) is a phosphoric acid compound of said metal.

4. The composition according to claim 1, wherein the hydroxyl group-containing organic resin contains at least one hydroxyl (OH) group, or at least one hydroxyl (OH) group and at least one of glycidyl, aldehyde and amino groups, in an amount of at least 0.04 equivalent per 100 g of the hydroxyl group-containing organic resin.

5. The composition according to claim 1, which contains, per 100 g of the hydroxyl group-containing organic resin, 2 to 50 g of the phosphoric acid and 0.015 to 1.5 gram molecules of a phosphoric acid compound of said metal.

6. The composition according to claim 1, wherein the colloid or sol or the powder has a particle size of 1 to 30 nm.

7. The composition according to claim 1, wherein the colloid or sol or the powder is used in an amount of 3 to 300 parts by weight per 100 parts by weight of the hydroxyl group-containing organic resin.

8. A surface-treated metal sheet comprising

(i) a member selected from the group consisting of a metal sheet, a metal-plated steel sheet and a metal alloy-plated steel sheet, and

(ii) a coating film formed on the surface of said member (i) by applying the surface-treating composition of claim 1 to the surface of said member, followed by drying, wherein said coating film has a coating weight of 0.1 to 3.0 g/m² on dry basis.

9. A surface-treated metal sheet comprising

(i) a member selected from the group consisting of a metal sheet, a metal-plated steel sheet and a metal alloy-plated steel sheet,

(ii) a corrosion-resistant coating film formed on said member (i), and

(iii) a coating film of an organic resin formed on the corrosion-resistant coating film (ii),

wherein the corrosion-resistant coating film (ii) is formed by applying the surface-treating composition of claim 1 to the surface of said member (i),

wherein the organic resin contained in coating film (iii) is at least one resin selected from the group consisting of an organic resin prepared by copolymerization of at least two members selected from the group consisting of methyl methacrylate, butyl acrylate, styrene, glycidyl methacrylate, methacrylic acid, acrylic acid, organic phosphorus monomer and hydroxyethyl acrylate;

olefin/acrylic acid copolymer resins;

polyacrylic acid and copolymer resins thereof;

polyacrylic acid ester and copolymer resins thereof;

polymethacrylic acid ester and copolymer resins thereof;

epoxy resin;

acryl-modified epoxy resins;

ester-modified epoxy resins;

urethane-modified epoxy resins;

urethane-modified epoxy ester resins;

vinyl-modified epoxy resins and vinyl-modified epoxy ester resins, and

wherein the coating film of the organic resin (iii) has a coating weight of 0.2 to 3.0 g/m² on dry basis.

10. A surface-treated metal sheet comprising

(i) a member selected from the group consisting of a metal sheet, a metal-plated steel sheet and a metal alloy-plated steel sheet,

(ii) a corrosion-resistant coating film formed on said member, and

(iii) a coating film of a coating composition which comprises an organic resin and a colloid or sol or a powder and which is formed on the corrosion-resistant coating film (ii),

wherein the corrosion-resistant coating film (ii) is formed by applying the surface-treating composition of claim 1 to the surface of said member (i),

wherein the organic resin contained in the coating composition for forming the coating film (iii) is at least one resin selected from the group consisting of an organic resin prepared by copolymerization of at least two members selected from the group consisting of methyl methacrylate, butyl acrylate, styrene, glycidyl methacrylate, methacrylic acid, acrylic acid, organic phosphorus monomer and hydroxyethyl acrylate;

olefin/acrylic acid copolymer resins;

polyacrylic acid and copolymer resins thereof;

polyacrylic acid ester and copolymer resins thereof;

polymethacrylic acid ester and copolymer resins thereof;

epoxy resin;

acryl-modified epoxy resin;

ester-modified epoxy resin;

urethane-modified epoxy resin;

urethane-modified epoxy ester resin;

vinyl-modified epoxy resin and vinyl-modified epoxy ester resin, and

wherein the colloid or sol or the powder contained in the coating composition for forming the coating film (iii) is used in an amount of 10 to 60 parts by weight, per 100 parts by weight of the organic resin, and

wherein the colloid or sol or powder is selected from the group consisting of SiO₂, Fe₂ O₃, Fe₃ O₄, MgO, ZrO₂, SnO₂, Al₂ O₃ and Sb₂ O₅, and

wherein the coating film (iii) of the coating composition has a coating weight of 0.2 to 3.0 g/m² on dry basis.

11. A surface-treated metal article comprising

(i) a metal substrate,

(ii) a corrosion-resistant coating film formed on said metal substrate,

wherein the corrosion-resistant coating film (ii) is formed by applying the surface-treating composition of claim 1 to the metal substrate (i), followed by drying.

12. A surface-treated metal article comprising

(i) a metal substrate,

(ii) a corrosion-resistant coating film formed on said metal substrate, and

(iii) a coating film of a coating composition which comprises an organic resin and if desired a colloid or sol or a powder and which is formed on the corrosion-resistant coating film (ii),

wherein the corrosion-resistant coating film (ii) is formed by applying the surface-treating composition of claim 1 to the metal substrate (i), followed by drying,

wherein the organic resin contained in the coating composition for forming the coating film (iii) is at least one member selected from the group consisting of an organic resin prepared by copolymerization of at least two members selected from the group consisting of methyl methacrylate, butyl acrylate, styrene, glycidyl methacrylate, methacrylic acid, acrylic acid, organic phosphorus monomer and hydroxyethyl acrylate;

olefin/acrylic acid copolymer resins;

polyacrylic acid and copolymer resins thereof;

polyacrylic acid ester and copolymer resins thereof;

polymethacrylic acid ester and copolymer resins thereof;

epoxy resin;

acryl-modified epoxy resin;

ester-modified epoxy resin;

urethane-modified epoxy resin;

urethane-modified epoxy ester resin;

vinyl-modified epoxy resin and vinyl-modified epoxy ester resin, and

wherein the colloid or sol or the powder, if contained in the coating composition for forming the coating film (iii), is used in an amount of 10 to 60 parts by weight, per 100 parts of the organic resin, and

wherein the colloid or sol or powder is selected from the group consisting of SiO₂, Fe₂ O₃, Fe₃ O₄, MgO, ZrO₂, SnO₂, Al₂ O₃ and Sb₂ O₅, and

wherein the coating film (iii) of the coating composition has a coating weight of 0.2 to 3.0 g/m² on dry basis.