Coating compositions exhibiting corrosion resistance properties and related coated substrates

• US 8,231,970 B2
• Filed: 12/14/2007
• Issued: 07/31/2012
• 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: Walters, David N., Schneider, John R.
• Primary Examiner(s): Feely, Michael J
• Application Number:
  US11/956,542
• Publication Number:
  US 20080090069A1
• Time in Patent Office: 1,691 Days
• Field of Search: 427/402, 427/404, 427/406, 427/407.1, 427/409, 427/410, 427/419.1, 427/419.2, 427/419.6, 427/419.8, 428/414, 428/416, 428/418, 428/446, 428/447, 428/448, 428/530, 523/440, 523/442, 523/443, 523/457, 524/492, 524/433, 528/10
• US Class Current: 428/418
• CPC Class Codes: C08F 283/006 on to polymers provided for in C08G18/00 C08F283/004 takes precedence
• CPC Class Codes: C08F 290/06 Polymers provided for in subclass C08G
• CPC Class Codes: C08F 299/06 from polyurethanes
• CPC Class Codes: C08G 18/3206 aliphatic
• CPC Class Codes: C08G 18/672 Esters of acrylic or alkyl acrylic acid having only one group containing active hydrogen
• CPC Class Codes: C08K 2003/222 Magnesia, i.e. magnesium oxide
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08L 23/26 modified by chemical after-treatment
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 2666/20 Macromolecular compounds having nitrogen in the main chain according to C08L75/00 - C08L79/00; Derivatives thereof
• CPC Class Codes: C08L 27/00 Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
• CPC Class Codes: C09D 123/26 modified by chemical after-treatment
• CPC Class Codes: C09D 175/16 having terminal carbon-to-carbon unsaturated bonds
• CPC Class Codes: C09D 4/06 Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
• CPC Class Codes: C09D 5/002 Priming paints C09D5/08 takes precedence
• CPC Class Codes: C09D 5/084 Inorganic compounds
• CPC Class Codes: C09D 7/67 Particle size smaller than 100 nm
• CPC Class Codes: Y10T 428/258 Alkali metal or alkaline earth metal or compound thereof
• CPC Class Codes: Y10T 428/31522 Next to metal
• CPC Class Codes: Y10T 428/31529 Next to metal

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 method for enhancing the corrosion resistance of a substrate comprising aluminum, the method comprising coating at least a portion of the substrate with a composition comprising:

(a) a thermosetting film-forming resin comprising a polyamine and an epoxy functional polymer; and

(b) corrosion resisting particles comprising magnesium oxide articles having a surface area of at least 10 square meters per gram, wherein the magnesium oxide particles have an average particle size of no more than 50 nanometers.

2. The method of claim 1, wherein the polyamine comprises a polyamide resin.

3. The method of claim 1, wherein the composition further comprises an adhesion promoting component comprising at least one of:

(a) tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, malonic acid, a derivative thereof, or a mixture thereof;

(b) a metal phosphate;

(c) an organophosphate;

(d) an organophosphonate; and

(e) a phosphatized epoxy resin.

4. The method of claim 1, wherein the composition further comprises a phenolic resin.

5. The method of claim 1, wherein the composition further comprises an alkoxysilane.

6. The method of claim 5, wherein the alkoxysilane comprises an epoxy-functional silane.

7. The method of claim 1, wherein the substrate further comprises a chromate conversion coating.

8. The method of claim 1, wherein the composition further comprises at least one of an organophosphate;

an organophosphonate; and

a phosphatized epoxy resin.

9. The method of claim 1, wherein the magnesium oxide particles have a surface area of 30 to 500 square meters per gram.

10. A method for enhancing the corrosion resistance of a substrate comprising aluminum, the method comprising coating at least a portion of the substrate with a composition comprising:

(a) a thermosetting film-forming resin comprising a polyamine and an epoxy functional polymer; and

(b) corrosion resisting particles comprising magnesium oxide particles having a surface area of at least 10 square meters per gram and an average primary particle size of no more than 200 nanometers.

11. A method for enhancing the corrosion resistance of a substrate comprising aluminum, the method comprising coating at least a portion of the substrate with a composition comprising:

(a) a thermosetting film-forming resin comprising a polyamine and an epoxy functional polymer; and

(b) corrosion resisting particles comprising magnesium oxide particles having a surface area of at least 10 square meters per gram;

wherein the substrate further comprises a chromate conversion coating.

12. A substrate comprising aluminum at least partially coated with a primer coating comprising:

(a) a thermoset film-forming resin comprising a polyamine and an epoxy functional polymer; and

(b) magnesium oxide particles having a surface area of at least 10 square meters per gram and an average particle size of no more than 50 nanometers;

wherein the magnesium oxide particles are dispersed in the thermoset film-forming resin.

13. The substrate of claim 12, wherein the coating further comprises a phenolic resin and/or an alkoxysilane.

14. The substrate of claim 12, wherein the substrate is clad with pure aluminum or further comprises a chromate conversion coating.

15. The substrate of claim 12, wherein the coating further comprises an adhesion promotion component comprising at least one of:

(a) tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, malonic acid, a derivative thereof, or a mixture thereof;

(b) a metal phosphate;

(c) an organophosphate;

(d) an organophosphonate; and

(e) a phosphatized epoxy resin.

16. The substrate of claim 12, wherein the coating further comprises an alkoxysilane.

17. The substrate of claim 16, wherein the alkoxysilane comprises an epoxy-functional silane.

18. The substrate of claim 12, wherein the substrate further comprises a chromate conversion coating.

19. The substrate of claim 12, wherein the composition further comprises at least one of an organophosphate;

an organophosphonate; and

a phosphatized epoxy resin.

20. The substrate of claim 12, wherein the magnesium oxide particles have a surface area of 30 to 500 square meters per gram.

21. A substrate comprising aluminum at least partially coated with a primer coating comprising:

(a) a thermoset film-forming resin comprising a polyamine and an epoxy functional polymer;

(b) magnesium oxide particles having a surface area of at least 10 square meters per gram and an average primary particle size of no more than 200 nanometers wherein the magnesium oxide particles are dispersed in the thermosetting film-forming resin.

22. A substrate comprising aluminum at least partially coated with a primer coating comprising:

(a) a thermoset film-forming resin comprising a polyamine and an epoxy functional polymer; and

(b) magnesium oxide particles having a surface area of at least 10 square meters per gram;

wherein the magnesium oxide particles are dispersed in the thermoset film-forming resin; and

wherein the substrate further comprises a chromate conversion coating.

23. A primer and/or pretreatment coating composition, comprising;

(a) a polyacrylate, wherein the polyacrylate comprises a urethane acrylate;

(b) a polythiol; and

(c) corrosion resisting particles comprising magnesium oxide particles having a surface area of at least 10 square meters per gram, and an average particle size of no more than 50 nanometers.

24. The primer and/or pretreatment coating composition of claim 23, further comprising an adhesion promoting component comprising at least one of:

(a) tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, malonic acid, a derivative thereof, or a mixture thereof;

(b) a metal phosphate;

(c) an organophosphate;

(d) an organophosphonate; and

(e) a phosphatized epoxy resin.

25. A substrate comprising aluminum at least partially coated with the composition of claim 23.

26. The substrate of claim 25, wherein the substrate is clad with pure aluminum or further comprises a chromate conversion coating.

27. The primer and/or pretreatment coating composition of claim 23, wherein the magnesium oxide particles have a surface area of 30 to 500 square meters per gram.

28. A primer and/or pretreatment coating composition comprising:

(a) a polyacrylate, wherein the polyacrylate comprises a urethane acrylate;

(b) a polythiol; and

(c) corrosion resisting particles comprising magnesium oxide particles having a surface area of at least 10 square meters per gram and an average particle size of no more than 200 nanometers.

29. A primer and/or pretreatment coating composition comprising:

(a) a polyacrylate, wherein the polyacrylate comprises a urethane acrylate;

(b) a polythiol; and

(c) corrosion resisting particles consisting of magnesium oxide particles having a surface area of at least 10 square meters per gram.