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

• US 8,288,000 B2
• Filed: 08/13/2007
• Issued: 10/16/2012
• 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: Ragunathan, Kaliappa G., Schneider, John R.
• Primary Examiner(s): Feely, Michael J
• Application Number:
  US11/837,742
• Publication Number:
  US 20070275256A1
• Time in Patent Office: 1,891 Days
• Field of Search: None
• US Class Current: 428/331
• 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, wherein the adhesion promoting component comprises at least one of a free acid, ester of a free acid, amide of a free acid, metal complex of a free acid, organophosphate, organoohosohonate, and phosphatized epoxy resin, and wherein the free acid is selected from the group consisting of tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, and malonic acid, and wherein the composition comprises 0.05 to 20 wt. % of the adhesion promoting component based on the total weight of the coating composition;

(b) corrosion resisting particles comprising an inorganic oxide network comprising a molecular chain of two or more different inorganic materials chemically connected to each other through one or more oxygen atoms, wherein the two or more different inorganic materials comprise;

(i) silicon; and

(ii) at least one of zinc, zirconium, cerium, yttrium, manganese, magnesium, and calcium; and

(c) a film forming resin,

wherein the coating composition is non-aqueous.

2. The coating composition of claim 1, wherein the composition is an etch primer.

3. The coating composition of claim 1, wherein the composition is substantially free of chromium containing material.

4. The coating composition of claim 1, wherein the particles comprising the inorganic oxide network are formed from hydrolysis of metal salts.

5. The coating composition of claim 1, wherein the particles comprising the inorganic oxide network are ultrafine particles.

6. The coating composition of claim 1, wherein the film-forming resin comprises a polyvinyl polymer.

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

8. The coating composition of claim 1, wherein the composition further comprises corrosion resisting particles comprising a clay.

9. The coating composition of claim 1, wherein the corrosion resisting particles have an average primary particle size of no more than 500 nanometers.

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

11. A multi-component composite coating deposited on a metal substrate comprising:

a first coating layer deposited on at least a portion of the substrate, wherein the first coating layer comprises the coating composition according to claim 1; and

a second coating layer deposited on at least a portion of the first coating layer.

12. The multi-component composite coating of claim 11, wherein the second coating layer is pigmented.