Coating compositions exhibiting corrosion resistance properties, related coated substrates, and methods

• US 7,811,670 B2
• Filed: 08/13/2007
• Issued: 10/12/2010
• Est. Priority Date: 08/26/2005
• Status: Active Grant

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Schneider, John R., Ragunathan, Kaliappa G.
• Primary Examiner(s): Feely; Michael J
• Application Number:
  US11/837,776
• Publication Number:
  US 20080022886A1
• Time in Patent Office: 1,156 Days
• Field of Search: None
• US Class Current: 428/457
• 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 ultrafine solid particles are also disclosed.

Claims

1. A coating composition comprising:

(a) an adhesion promoting component comprising at least one material selected from the group consisting of a free acid, a phosphatized epoxy resin, a metal phosphate, an organophosphate, and an organophosphonate; and

(b) preformed chemically modified particles having an average primary particle size of no more than 500 nanometers,

wherein the preformed chemically modified particles comprise silica particles chemically modified by reaction of the particles with trimethoxysilylpropyl methacrylate and vinyl trimethoxysilane;

wherein the free acid is selected from the group consisting of tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, malonic acid, derivatives thereof, and mixtures thereof; and

wherein the composition is substantially free of chromium containing material.

2. The coating composition of claim 1, further comprising a film-forming resin.

3. The coating composition of claim 2, wherein the weight ratio of the chemically modified particles to the film-forming resin in the composition is less than 0.2:

1.

4. The coating composition of claim 2, wherein the film-forming resin comprises a polyvinyl polymer.

5. The coating composition of claim 1, wherein the composition further comprises a phenolic resin and an alkoxysilane.

6. A metal substrate at least partially coated with the coating composition of claim 1.

7. A coating composition comprising:

(a) an adhesion promoting component comprising at least one material selected from the group consisting of a free acid, a phosphatized epoxy resin, a metal phosphate, an organophosphate, and an organophosphonate;

(b) preformed chemically modified particles having an average primary particle size of no more than 500 nanometers,

wherein the preformed chemically modified particles comprise silica particles chemically modified by reaction of the particles with trimethoxysilylpropyl methacrylate and vinyl trimethoxysilane; and

(c) a film-forming resin;

wherein the free acid is selected from the group consisting of tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, malonic acid, derivatives thereof, and mixtures thereof; and

wherein the composition is solvent-borne and substantially free of chromium containing material.

8. A method for enhancing the corrosion resistance of a metal substrate, comprising coating at least a portion of a bare or pretreated metal substrate with a primer composition that comprises:

(a) an adhesion promoting component comprising at least one material selected from the group consisting of a free acid, a phosphatized epoxy resin, a metal phosphate, an organophosphate, and an organophosphonate, and

(b) preformed chemically modified particles having an average primary particle size of no more than 500 nanometers,

wherein the preformed chemically modified particles comprise silica particles chemically modified by reaction of the particles with trimethoxysilylpropyl methacrylate and vinyl trimethoxysilane;

wherein the free acid is selected from the group consisting of tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, malonic acid, derivatives thereof, and mixtures thereof; and

wherein the composition is substantially free of chromium containing material.