US2004086718A1PendingUtilityA1

Corrosion and alkali-resistant compositions and methods for using the same

33
Individually held — no corporate assignee on recordPriority: Nov 6, 2002Filed: Nov 6, 2002Published: May 6, 2004
Est. expiryNov 6, 2022(expired)· nominal 20-yr term from priority
Inventors:Michael J. PawlikDennis W. JonesRalph C. GrayRichard M. Nugent, Jr.Yves DisertLaurent Deronne
Y10T428/31515C08G 59/4071Y10T428/265C08G 59/1488C09D 163/00Y10T428/31529Y10T428/31522Y10T428/31678C09D 5/08Y10T428/31511
33
PatentIndex Score
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Claims

Abstract

A corrosion resistant, alkali resistant coating composition is disclosed. The composition comprises a binder comprising a reaction product of an epoxy-containing material and a phosphorus-containing material together with a curing agent. Aminoplasts, especially melamine-based aminoplasts, are particularly suitable curing agents. A source of silicon can optionally be included. The compositions also provide excellent adhesion and can be used with or without a weldable primer. The compositions are applied to and cured on a metal substrate.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A composition substantially free from conductive pigments comprising: 
 a) the reaction product of one or more epoxy-containing materials and one or more phosphorus-containing materials; and    b) a curing agent.    
     
     
         2 . The composition of  claim 1 , wherein the epoxy-containing material is a polyglycidyl ether of a polyhydric phenol.  
     
     
         3 . The composition of  claim 2 , wherein the polyhydric phenol is Bisphenol A.  
     
     
         4 . The composition of  claim 1 , wherein the number average molecular weight of the epoxy-containing material is 220 to 25,000, as determined by multiplying the epoxy equivalent by the epoxy functionality.  
     
     
         5 . The composition of  claim 4 , wherein the molecular weight of the epoxy-containing material is 220 to 4500.  
     
     
         6 . The composition of  claim 1 , wherein the phosphorus-containing material is selected from the group consisting of phosphoric acid, a phosphonic acid, and phosphorous acid.  
     
     
         7 . The composition of  claim 1 , wherein the equivalent ratio of the phosphorus-containing material to epoxy-containing material is between 0.5 and 3.5:1.  
     
     
         8 . The composition of  claim 1 , wherein the curing agent is selected from the group consisting of aminoplast resins, polyisocyanates, polyacids, organometallic complexed materials, polyamines, and polyamides.  
     
     
         9 . The composition of  claim 7 , wherein the curing agent is an aminoplast.  
     
     
         10 . The composition of  claim 9 , wherein the aminoplast is a melamine-formaldehyde condensate.  
     
     
         11 . The composition of  claim 10 , wherein the melamine-formaldehyde condensate comprises at least 40 weight percent of imino groups.  
     
     
         12 . The composition of  claim 1 , wherein the number average molecular weight of a) is from 1000 to 5000.  
     
     
         13 . The composition of  claim 1 , wherein the weight percent of (a) is from 50 to 100, based on the total weight of the composition.  
     
     
         14 . The composition of  claim 1 , wherein the weight percent of (b) is from 5 to 25, based on the total weight of the resinous binder.  
     
     
         15 . The composition of  claim 1 , further comprising one or more corrosion resistant pigments.  
     
     
         16 . The composition of  claim 1 , wherein said composition is aqueous-based.  
     
     
         17 . The composition of  claim 1 , wherein said composition is solvent-based.  
     
     
         18 . A composition comprising: 
 a) the reaction product of one or more epoxy-containing materials and one or more phosphorus-containing materials;    b) a curing agent; and    c) a source of silicon.    
     
     
         19 . The composition of  claim 18 , wherein the weight percent of (a) is from 50 to 100, based on the total weight of the composition.  
     
     
         20 . The composition of  claim 18 , wherein the weight percent of (b) is from 5 to 25, based on the total weight of the resinous binder.  
     
     
         21 . The composition of  claim 18 , wherein the weight ratio of (c) is from 1.0 to 30, based on the total weight of the composition.  
     
     
         22 . The composition of  claim 18 , wherein the weight ratio of (c) to (b) is from 0.01 to 1.0.  
     
     
         23 . A process for coating a metal substrate comprising: 
 a) applying the composition of  claim 1  to the metal substrate, wherein the composition is at a temperature of 10° C. to 85° C.;    b) curing the coating composition on the metal sheet.    
     
     
         24 . The process of  claim 23 , wherein the metal substrate is selected from the group comprising ferrous metals, non-ferrous metals, and combinations thereof.  
     
     
         25 . The process of  claim 23 , wherein the metal substrate is galvanized before application of the composition.  
     
     
         26 . A metal substrate coated by the process of  claim 23 .  
     
     
         27 . A coating layer combination comprising an anti-corrosion layer formed from the composition of  claim 1 , directly adjacent to a weldable coating layer comprising an electroconductive pigment and a binder.  
     
     
         28 . A coating layer combination comprising an anti-corrosion layer formed from the composition of  claim 18 , directly adjacent to a weldable coating layer comprising an electroconductive pigment and a binder.  
     
     
         29 . A weldable, corrosion resistant layer deposited on a substrate, wherein the weldable layer is less than or equal to 2.2 microns, is substantially free of conductive pigments, and is comprised of the cured reaction product of: 
 a) a reaction product of at least one epoxy-functional material and at least one phosphorus-containing material;    b) a curing agent; and    c) silicon.    
     
     
         30 . The layer of  claim 29 , wherein the epoxy-containing material is a polyglycidyl ether of a polyhydric phenol.  
     
     
         31 . The composition of  claim 30 , wherein the polyhydric phenol is Bisphenol A.  
     
     
         32 . The composition of  claim 29 , wherein the number average molecular weight of the epoxy-containing material is 220 to 25,000, as determined by multiplying the epoxy equivalent by the epoxy functionality.  
     
     
         33 . The composition of  claim 29 , wherein the phosphorus-containing material is selected from the group consisting of phosphoric acid, a phosphonic acid, and phosphorous acid.  
     
     
         34 . The composition of  claim 29 , wherein the curing agent is selected from the group consisting of aminoplast resins, polyisocyanates, polyacids, organometallic complexed materials, polyamines, and polyamides.  
     
     
         35 . The composition of  claim 34 , wherein the curing agent is an aminoplast.  
     
     
         36 . The composition of  claim 35 , wherein the aminoplast is a melamine-formaldehyde condensate.  
     
     
         37 . The composition of  claim 36 , wherein the melamine-formaldehyde condensate comprises at least 40 weight percent of imino groups.  
     
     
         38 . The composition of  claim 29 , wherein the number average molecular weight of a) is from 1000 to 5000.  
     
     
         39 . A weldable, corrosion resistant layer deposited on a substrate, wherein the weldable layer is of a thickness to provide corrosion resistance without inhibiting welding, is substantially free of conductive pigments, and is comprised of the cured reaction product of: 
 a) the reaction product of at least one epoxy-functional material and at least one phosphorus-containing material; and    b) a curing agent.    
     
     
         40 . The layer of  claim 39 , wherein said layer is greater than 0.1 micron and less than 1.0 micron.  
     
     
         41 . A method for improving the alkaline resistance of a pretreatment layer, comprising adding an aminoplast to the composition from which the layer is deposited.  
     
     
         42 . A coating multilayer comprising: 
 a) a nonchrome alkaline resistant pretreatment layer; and    b) a coating deposited on the nonchrome alkaline resistant pretreatment layer;    wherein <10 percent of the coating is removed by alkaline cleaning with an alkaline cleaner having a pH of 13 or higher.

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