Direct to substrate coatings

• US 20060063872A1
• Filed: 01/14/2005
• Published: 03/23/2006
• Est. Priority Date: 01/16/2004
• Status: Abandoned Application

• Current Assignee: Deft, Incorporated (Nouryon BV)
• Original Assignee: Deft, Incorporated (Nouryon BV)
• Inventors: Teachout, Laurence R., Albers, Richard A., Morris, Eric M.
• Application Number:
  US11/036,416
• Publication Number:
  US 20060063872A1
• Time in Patent Office: Days
• US Class Current: 524/417
• CPC Class Codes: C08J 7/12 Chemical modification
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/24 Acids; Salts thereof C08K3/16 takes precedence
• CPC Class Codes: C08K 3/28 Nitrogen-containing compounds
• CPC Class Codes: C08K 3/30 Sulfur-, selenium- or tellurium-containing compounds
• CPC Class Codes: C08L 101/04 containing halogen atoms
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/14 Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C08L 27/12 containing fluorine atoms
• CPC Class Codes: C08L 67/00 Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08L77/12; of polyester-imides C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C09D 127/12 containing fluorine atoms
• CPC Class Codes: C09D 167/00 Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain based on polyester-amides C09D177/12; based on polyester-imides C09D179/08; Coating compositions based on derivatives of such polymers
• CPC Class Codes: C09D 5/082 characterised by the anti-corrosive pigment
• CPC Class Codes: C09D 5/084 Inorganic compounds
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31678 Of metal

Abstract

Corrosion-inhibiting coating compositions which are self-priming topcoats having improved weatherability and durability are provided. The compositions contain fluorinated resins (binders), incorporate one or more corrosion-inhibiting compounds including corrosion-inhibiting extenders (a metal cation from Group I A or II A of the periodic table of the elements and an oxyanion counterion), corrosion-inhibiting rare earth compounds, and corrosion-inhibiting carbon pigments. Methods for applying the corrosion-inhibiting compositions to a substrate are also provided.

Claims

1. A curable corrosion-inhibiting coating composition comprising:

a fluorinated binder; and

an effective amount of a corrosion-inhibiting compound selected from the group consisting of one or more of a corrosion-inhibiting extender, a corrosion-inhibiting rare earth compound, and a corrosion-inhibiting carbon pigment, and combinations thereof.

2. A coating composition according to claim 1 wherein the coating composition is capable of binding to an underlying substrate without an intermediate polymeric coating and capable of providing corrosion protection to the underlying substrate.

3. A coating composition according to claim 1 wherein the fluorinated binder is a fluorinated vinyl ether.

4. A coating composition according to claim 1 further comprising an additive.

5. A coating composition according to claim 1 further comprising one or more corrosion inhibiting co-inhibitors.

6. A coating composition according to claim 5 wherein the co-inhibitor is selected from the group consisting of amine containing compounds, sulfur containing compounds, phosphorus containing compounds, polyaniline, ionic exchange resins, amino acids, derivatives of amino acids, dextrins, cyclodextrins, and combinations thereof.

7. A coating composition according to claim 1 wherein the corrosion-inhibiting compound is present in the composition in a pigment volume concentration of about 0.1% to about 65%.

8. A corrosion-inhibiting coating composition according to claim 1 wherein the corrosion-inhibiting compound is a corrosion-inhibiting extender, present in the composition in an amount from about 45 wt % to about 75 wt % of the solid components present in the composition.

9. A coating composition according to claim 8 wherein the extender is selected from a group consisting of metal cation sulfates, metal cation phosphates, metal cation nitrates, metal cation silicates, and combinations thereof.

10. A coating composition according to claim 9 wherein the metal cation is selected from the group consisting of barium, strontium, and calcium, and combinations thereof.

11. A coating composition according to claim 9 wherein the metal cation is selected from the group consisting of yttrium, a lanthanide, and combinations thereof.

12. A corrosion-inhibiting coating composition according to claim 1 wherein the corrosion-inhibiting compound is a corrosion-inhibiting rare earth compound.

13. A coating composition according to claim 12 wherein the rare earth compound is selected from the group consisting of praseodymium oxides, praseodymium hydroxides, praseodymium solid solution mixed oxides, a mixture of praseodymium oxides, a mixture of praseodymium hydroxides, praseodymium nitrate, praseodymium sulfate, praseodymium phosphate, and combinations thereof.

14. A corrosion-inhibiting coating composition according to claim 1 wherein the corrosion-inhibiting compound is a corrosion inhibiting carbon pigment.

15. A coating composition according to claim 14 wherein the carbon pigment is a surface or pH modified carbon pigment.

16. A coating composition according to claim 1 further comprising

a polyester resin blend;

a dispersing agent; and

a color pigment,

wherein the corrosion-inhibiting compound is a combination of a corrosion-inhibiting extender and a corrosion-inhibiting rare earth compound.

21. A method for coating a substrate comprising:

pretreating the substrate with a conversion treatment;

applying a composition according to claim 1;

and

curing the applied composition.

22. A method according to claim 21 wherein the conversion treatment is selected from the group consisting of cerium conversion coatings, praseodymium conversion coatings, phosphate conversion coatings, zinc-type conversion coatings, anodized coatings, anodized and sealed coatings, and chromium conversion coatings.

23. A method according to claim 22 wherein the conversion treatment is a chromium conversion treatment.

24. A method according to claim 21 wherein the substrate is formed from a material selected from the group consisting of aluminum, aluminum alloys, bare steel, galvanized steel, zinc, zinc alloys, magnesium, magnesium alloys, and composite materials.

25. A method according to claim 24 wherein the material is an aluminum or an aluminum alloy.

26. A method according to claim 21 wherein the substrate is a polymer coated material.

30. A method for coating a substrate comprising applying a corrosion-inhibiting coating composition according to claim 1 directly to a substrate without an intermediate polymeric coating between the substrate and the corrosion-inhibiting coating.

17. A substrate directly coated with a cured coating composition, the coating composition comprising:

a fluorinated binder; and

an effective amount of a corrosion-inhibiting compound selected from the group consisting of a corrosion-inhibiting extender, a corrosion-inhibiting rare earth compound, a corrosion-inhibiting carbon pigment, and combinations thereof.

18. A substrate according to claim 17 wherein the substrate is formed from a material selected from the group consisting of aluminum, aluminum alloys, bare steel, galvanized steel, zinc, zinc alloys, magnesium, and magnesium alloys, and composite materials.

19. A substrate according to claim 18 wherein the material is an aluminum or an aluminum alloy.

20. A substrate according to claim 17 wherein the substrate is a polymer coated material.

27. A method for coating a substrate comprising:

preparing a coating base, the coating base having a fluorinated binder and one or more corrosion-inhibiting compounds;

adding a catalyst to the coating base to form a mixture; and

applying the mixture to the substrate.

28. A method according to claim 27 wherein the catalyst is an isocyanate catalyst.

29. A method according to claim 27 wherein one or more of the corrosion-inhibiting compounds is selected from the group consisting of a corrosion-inhibiting extender, a corrosion-inhibiting rare earth compound, and a corrosion-inhibiting carbon pigment.