CN101512044B - 在含锌的金属上的非铬的薄有机-无机混合涂层 - Google Patents
在含锌的金属上的非铬的薄有机-无机混合涂层 Download PDFInfo
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Classifications
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/34—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides
- C23C22/36—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides containing also phosphates
- C23C22/364—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides containing also phosphates containing also manganese cations
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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- C09D5/002—Priming paints
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/40—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing molybdates, tungstates or vanadates
- C23C22/42—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing molybdates, tungstates or vanadates containing also phosphates
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/40—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing molybdates, tungstates or vanadates
- C23C22/44—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing molybdates, tungstates or vanadates containing also fluorides or complex fluorides
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/27—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
- Y10T428/273—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.] of coating
Abstract
本发明涉及一种用于薄有机/无机混合涂层在含锌的金属表面上沉积的处理溶液,该处理溶液包含水和(i)一定浓度的磷酸(A);(ii)一定浓度的溶解的无机组分(B),该无机组分(B)包含选自钛、锆、铪和/或硅的至少一种络合的氟金属化物阴离子,优选六氟钛酸;(iii)一定浓度的溶解的无机组分(C),该无机组分(C)由锌(C1)和/或锰(C2)的二价阳离子组成;(iv)一定浓度的溶解的无机组分(D),该无机组分(D)由钼的含氧阴离子组成;(v)一定浓度的水溶性和/或水分散性聚合物(E),该聚合物(E)基于螯合聚(乙烯基苯酚)化合物;(vi)一定浓度的水溶性和/或水分散性聚合树脂(F),该聚合树脂(F)不是组分(E)的部分或者与组分(E)不同。在含锌的金属表面上的薄有机/无机混合涂层根据本发明以至少约0.4g/m2且不大于约1.6g/m2的膜重量沉积,赋予所涂布的材料以暂时的腐蚀防护和优异的对进一步施加的有机涂层的粘附性降低。另外,本发明涉及涂有有机/无机混合涂层的含锌的金属基底在工业组装和形成程序中的用途,及在工业金属表面后整理如卷材涂布、车身涂漆线、白色家电和电子设备外壳生产中用于将多层涂层施加到所述基底的用途,该有机/无机混合涂层提供不大于1.5mΩ且优选不大于1mΩ的所述涂布的基底的表面电阻。
Description
本发明涉及一种用于薄的均匀有机-无机混合涂层在含锌的金属表面上沉积的处理溶液,其中所述涂层赋予处理过的金属以暂时的腐蚀防护和改善的对进一步施加的油漆和/或清喷漆的附着力。此外,本发明包括含锌的金属表面的处理方法,尤其在卷材涂布工业中的含锌的金属表面的处理方法,以及这种涂有了薄有机-无机混合涂层的金属基底在白色家电和电子设备外壳生产中的用途。
含锌的材料尤其镀锌或镀合金化锌的钢条的暂时腐蚀防护通常由防护油提供,或者如果需要通过如同磷化或铬酸盐钝化的转化处理提供。本文中的术语“转化处理”是指金属表面利用水溶液的处理,在处理过程中自然金属表面层转化成无机层,该无机层由来自水性处理溶液的阳离子和阴离子组成以及由以这样的方式处理的基体金属的阳离子组成。金属的转化处理的范围在于赋予金属以耐腐蚀的保护层,以及在于提供提升了金属表面和进一步施加的有机涂层之间的附着力的接合层。
在建筑或汽车工业或者用于电子市场或者在白色家电生产中的含锌的材料的表面后整理通常通过多步法实现,该多步法包括使金属表面脱除残余的油和硬水残余物或其它有机表面污染物的预处理步骤或脱脂步骤,通过转化处理的阻挡涂层的形成和有机涂层如底漆、油漆、清喷漆或电泳涂层的施加。取决于基底和涂层的具体要求,转化处理之后进行进一步有助于阻挡涂层的耐蚀性和附着性的另外的钝化漂洗。取决于金属基底,特别地引入随后的铬酸盐钝化漂洗,以消除磷酸盐涂层中的缺陷如显微孔隙和裂纹以及改善对无机阻挡涂层的油漆附着力。
在现有技术中,已经利用铬酸盐转化处理达到了关于腐蚀防护和对进一步施加的有机涂层的附着力的最好结果。用于建立有效的阻挡涂层的磷化方法是在汽车工业中经过充分证实的方法,但是本身是复杂的多步法,其需要浴参数的广泛控制并且与铬酸盐钝化方法相比还产生较少的装饰性涂层。因为这些铬酸盐涂层包含有害的六价铬,所以表面后处理工业旨在替代铬酸盐转化方法,因而遵循近来在欧盟刚生效的在关于废弃电气设备和电子设备(2002/95/EC)和关于废旧汽车的回收和循环(2000/53/EC;2005/673/EC)的EU指令基础上的国家和地区立法。已经作出了许多努力来开发含锌的金属的磷化方法,该磷化方法满足了暂时的腐蚀防护的要求并且还提供相当大的对施加到磷化后的锌基底上的有机涂层的附着力,而不需要另外的步骤如在磷化步骤之前的活化步骤和另外的钝化漂洗例如铬酸盐后处理。特别是,强烈支持“不漂洗”或“原位干燥”应用,因为它们提供了在其过程中形成阻挡涂层的一步法,该阻挡涂层还可以包括附着到待保护金属零件的第一有机层。
替代铬酸盐处理的后磷化漂洗公开于US 5298289中。这里,把还包含其门尼希(Mannich)衍生物的聚乙烯基苯酚化合物水溶液施加到转化处理过的金属表面,以增强表面的亲水性,因此使带有油漆和清喷漆的这些表面容易润湿。此外,这些聚合物能够与有机涂层交联,因而提供改善的对油漆体系的附着力。US 5298289还教导了包含聚乙烯基苯酚化合物的处理溶液还可以包含对于金属表面的转化处理来说典型的组分。此外,它已经暗示了利用聚乙烯基苯酚化合物作为有机成膜组合物如油漆和电泳涂体系中的添加组分,以改善有机涂层对于裸金属表面或转化处理过的金属表面的附着力。
US 2002/0011281描述了一种锌磷化溶液,该溶液还包含少量有机聚合物如络合取代的聚(4-乙烯基苯酚)化合物。根据本发明,当表面处理利用包含小于500ppm前述有机聚合物的磷化溶液进行时,能够省略铬酸盐钝化步骤。这种磷化方法产生了主要由膜重量大于3g/m2的磷酸锌层构成的无机涂层。该磷化处理尤其设计来与实现汽车工业的高质量标准不可缺少的随后的表面后处理步骤如施加电泳涂或粉末涂层组合。
用于锌基金属表面的腐蚀防护的另一种不含铬的处理溶液公开于US 2003/0150524中。根据该发明的处理溶液与典型的磷化浴不同,因为它还包含如钛和/或锆的络合氟化物,同时磷酸的量小于1.45g/l。另外,向处理溶液中添加了少量有机聚合物尤其是聚乙烯基苯酚的衍生物,以便替代在转化处理之后的另外的钝化漂洗,并从而减少磷化工业中另外的过程步骤。总而言之,该转化处理设计来提供主要由未表现出结晶性的无机磷酸盐层组成的薄保护性涂层,从而尤其可用于已经磷化的金属零件的切割边缘保护或用于例如在组装线中半完成产品的部分磷化的金属零件的处理。
取代的聚(4-乙烯基苯酚)化合物作为在与US 2003/0150524中描述的磷化浴相似的进一步包含成膜聚合物的磷化浴中的组分的应用公开于WO 99/19083和WO 00/71626中。再次引入聚(4-乙烯基苯酚)化合物,以促进交联至成膜聚合物的官能部分,因而增强有机涂层的附着力。应用这种表面处理自然地导致了有机-无机混合涂层的形成,因为转化过程和成膜聚合物分子的沉淀至少部分同时且彼此独立地发生。在这种混合涂层中,有机聚合物分子可以沉积在无机基质的微米孔或纳米孔中,因而充当在阻挡涂层内的粘合剂。此外,有机聚合物分子的引入可以显著增加由成膜聚合物组分提供的对有机涂层的附着力。由于分别地,转化层形成的过程是通过腐蚀金属表面引发的,而固化的过程中有机涂层的形成是通过处理溶液的干燥(“原位干燥”应用)而实现的,所以实质上重要的是相对于无机转化层的形成平衡成膜过程,以保证形成具有最佳的耐蚀性和附着力性质的有机-无机混合涂层。
WO 00/71626教导了仅存在既可以与成膜聚合物交联又可附着到无机基质上的聚(4-乙烯基苯酚)化合物不足以提供合理的耐蚀性能。根据WO 00/71626,因此为了实现具有适当的耐蚀性的有机-无机混合涂层,向涂层配方中添加有机膦酸是必须遵循的。按照WO 99/19083,公开了一种用于形成基于磷化化学的有机-无机混合涂层的配方,其不包含任何锰和锌的二价阳离子,以便相对于无机转化层的形成而平衡成膜过程。由现有技术磷化方法已知锰和/或锌离子的缺乏典型地导致了形成保护性较差的无机转化涂层,因为它们是形成速率的决定性参数,因而是阻挡涂层形态的决定性参数。大体上,用于基于磷化化学的有机-无机混合涂层的沉积的配方未能提供长期稳定性并且往往聚集残渣。这是由于这样的事实,即水分散性或水溶解的成膜聚合物主要由携带负电荷的官能部分如羧化物和/或羟基化物构成。因此,带负电荷的分散的聚合物颗粒或溶解的聚合物分子与阳离子尤其是在磷化化学中典型的二价或多价阳离子例如锌和/或锰的离子性相互作用,可能会导致聚合物颗粒在处理配方中的聚集以及沉淀。
不管与施加基于磷化化学的有机-无机混合涂层的领域中的方法有关的实质的现有技术,存在改善这种涂层的耐蚀性能的要求,尤其是通过调整控制沉积过程的参数改善这种涂层的耐蚀性能,以及存在为了赋予表面处理的技术方法以稳定性而配制展现出长期稳定性的处理溶液的要求。此外,在工业原位干燥应用中形成的混合涂层的性能受到残余的无机组分如磷酸盐、锌、锰和/或氟金属化物(fluoro metallate)的强烈影响,所述无机组分在转化过程中未沉积在金属表面并因而被俘获在有机基质内。这些残余物可能会引起混合涂层内的有机基质的化学退化过程,因此不得不避免或有效地处置。形成具有优异性质的有机-无机混合涂层的另一个先决条件在于提供导致金属表面被薄涂层均匀覆盖的配方。这对于其中在金属零件形成和组装之前不得不赋予金属材料以暂时的腐蚀防护的工业过程来说是尤其重要的。典型的应用可在金属加工工业中或者可以用于家用电器、白色家电和电子设备外壳的制造厂。具体地,电子工业设定了保证了它们外壳的有效屏蔽以保护它们的贵重设备免受电磁感应的破坏的高质量标准。在那个方面,有机-无机混合涂层在同时地展现出优异的耐蚀性能的同时,应当具有由相对小厚度的涂层提供的相当低的电阻,而反过来又至少需要被混合涂层均匀覆盖的金属基底。
令人惊讶的是,本发明人发现利用如下溶液处理含锌的金属表面如热浸镀锌、电解镀锌或锌镀层退火处理的钢表面或者任何其它合金化的或非合金化的锌表面,产生了具有优异的耐蚀性能、油漆附着力和防指纹污染的薄有机-无机混合涂层,该溶液包含水和
(i)一定浓度的磷酸(A);
(ii)一定浓度的溶解的无机组分(B),该无机组分(B)包含至少一种选自钛、锆、铪和/或硅的络合的氟金属化物阴离子,优选六氟钛酸;
(iii)一定浓度的溶解的无机组分(C),该无机组分(C)由锌(C1)和/或锰(C2)的二价阳离子组成;
(iv)一定浓度的溶解的无机组分(D),该无机组分(D)由钼的含氧阴离子组成;
(v)一定浓度的水溶性和/或水分散性聚合物(E),该聚合物(E)由一定数量(n)的x-(N-R1-N-R2-氨甲基)-4-羟基-苯乙烯单体单元组成,其中x=2,3,5或6表示取代位置序号,R1表示包含1至4个碳原子的烷基,而R2表示符合通式H(CHOH)mCH2-的取代基,其中m是3至5的整数,该聚合物(E)能够螯合组分(B)和/或(C);
(vi)一定浓度的水溶性和/或水分散性聚合树脂(F),该聚合树脂(F)不是组分(E)的部分或者与组分(E)不同。
水溶性和/或水分散性聚合物(E)优选符合下列结构通式(I)
其中,R1和R2为如上面所定义的取代基。
根据本发明,当以下列方式构成包含一定量的组分(C1)的处理溶液时,获得了具有最佳性能的有机-无机混合涂层,即锌阳离子(C1)与聚合物的螯合部分的摩尔比(C1)∶(n·E)接近于化学计量比且优选不大于0.75,但是为至少0.34,最优选为0.68,其中(n·E)为聚合物(E)的单体单元的数量(n)。在优选范围内的锌阳离子(C1)相对于螯合化合物(E)的比例阻止了成膜聚合物(F)的沉淀,因而赋予处理溶液以长期稳定性,并且在工业表面后处理的典型加工次数内在原位干燥应用过程中保证了有效的转化层形成,以及促进了残余的组分A-E引入到混合涂层中。化学计量过量的聚(乙烯基苯酚)化合物(E)引起不太有效的转化层形成。
本文中的化学计量比基于下列一般络合物形成反应:
nZn2++E→[ZnnE]2n+
其中的化学计量根据锌阳离子与聚(乙烯基苯酚)化合物(E)的单体单元的数量(n)的等摩尔转化。
在处理溶液不包含任何量的锌阳离子(C1)的情况下,锰阳离子(C2)与(n·E)为聚合物(E)的单体单元的数量(n)的聚合物的螯合部分的摩尔比(C2)∶(n·E)一定不大于0.62且优选不大于0.47,但是为至少0.22,最优选为0.42,以便为源自在根据本发明的处理过程中金属表面的酸洗的锌阳离子提供足量的螯合部分。
处理溶液的其它化合物的摩尔浓度应当进一步遵守下列特定的摩尔比:
(i)包含络合的氟金属化物阴离子的组分(B)的总当量氢浓度与磷酸(A)的当量氢浓度的摩尔比(B)∶(A)为至少0.1、优选为至少0.3、但是不大于0.6且优选不大于0.5,最优选为0.38。
(ii)组分(B)与(C1)的摩尔比(B)∶(C1)为至少2.0,但是不大于3.5且优选不大于2.5,最优选为2.3,和/或组分(B)与(C2)的摩尔比(B)∶(C2)为至少1.2,但是不大于2.4,优选不大于1.8,最优选为1.4;
(iii)组分(D)与(C1)的摩尔比(D)∶(C1)为至少1∶50,优选为至少1∶40,但是不大于1∶20且优选不大于1∶25,最优选为1∶30,或者组分(D)与(C2)的摩尔比(D)∶(C2)为至少1∶80,优选为至少1∶60,但是不大于1∶20且优选不大于1∶30,最优选为1∶45。
以这样的方式配制的处理溶液在高达至少30℃、优选为至少40℃的温度下和高达约45℃的温度下,提供对于溶解的、分散的或既溶解又分散的树脂(F)的离析和/或沉淀的长期稳定性。
为了保证有机-无机混合涂层的适当的沉积速率,处理溶液包含至少0.5重量%、优选为至少1.0重量%且最优选为至少2.0重量%、但是不大于3.0重量%的磷酸(A)在所述溶液中的质量份数,而处理溶液的剩余化合物的量由前述摩尔比预定义。
相对于二价阳离子的含量,处理溶液还可以以这样的方式配制,即所述溶液中的由溶解的无机化合物(C)提供的二价阳离子的总质量份数为至少0.2重量%,优选为至少0.4重量%,但是不大于1.2重量%且优选不大于0.8重量%,而处理溶液的剩余化合物的量由前述摩尔比预定义。
通常,可以根据常规工业涂布技术如浸渍、喷涂、擦拭和碾滚和/或辊筒施加,把处理溶液施加到金属表面上。
根据本发明,在处理溶液的施加之后,必须干燥利用这些涂布技术使其与处理溶液接触的金属表面。在涂布工业中,这种方法表示为原位干燥应用和/或不漂洗应用。在附着到金属表面上的处理溶液的挥发性化合物蒸发之后,形成混合涂层,该混合涂层主要由被组分(F)的均匀树脂涂层覆盖的金属表面上的无机转化层组成,该树脂涂层还包含残余的组分(A-D)。因为主要由无机组分构成的转化层的形成速率由组分(A-D)的相对量确定,所以在干燥之后获得的有机-无机混合涂层的最终膜重量能够根据处理溶液中的水溶性和/或水分散性聚合树脂(F)的量调整。
因此处理溶液中的水溶性和/或水分散性聚合树脂(F)的质量份数可以独立于其它组分进行选择,但是应当为至少5重量%,优选为至少15重量%,但是不大于50重量%且优选不大于25重量%,以如前所述得到至少约0.4g/m2、优选为至少0.6g/m2、但是不大于约1.6g/m2且优选不大于0.8g/m2的膜重量,以及保证具有所需性能的有机-无机混合涂层的形成。
根据本发明,表面处理过的金属零件的原位干燥方法还包括均匀混合涂层的形成,该均匀混合涂层是经由在不大于150℃、优选不大于120℃、但是为至少65℃且优选为至少80℃的峰值金属温度下的聚合树脂(F)的硬化和/或交联而形成的。因此,水溶性和/或水分散性聚合树脂(F)具有优选不高于80℃、更优选不高于60℃且最优选不高于45℃的成膜温度。聚合树脂(F)可以是除了前述先决条件之外能够硬化或交联的任何水分散性聚合物,如丙烯酸树脂、聚氨酯、酚醛塑料、乙烯基聚合物(vinyl)和环氧树脂。
本发明还包括如前所述的组分A-F的处理溶液,该处理溶液另外包含稳定分散的固体材料(G),该固体材料(G)以分离的形式时具有不大于0.35的静摩擦系数,该静摩擦系数是在固体材料本身和冷轧钢之间测量的,其中组分(G)与组分(F)的质量比为至少0.01,但是不大于1且优选为0.04。所述固体材料优选基于氧化的聚乙烯蜡。根据优选的量把蜡添加到处理溶液中减少了涂层的摩擦系数,这对金属条和卷材的形成和运输尤其重要。蜡的更高的量导致涂层的涂覆性能恶化。
本发明还包括通过根据本发明的方法获得的具有薄有机/无机混合涂层的含锌的金属基底,其中按照工业标准IBM SG-PR-000857利用4点电阻测量法测定的所述基底的表面电阻不大于1.5mΩ且优选不大于1mΩ。
具有膜重量为至少0.4g/m2、优选为至少0.6g/m2、但是不大于1.6g/m2且优选不大于0.8g/m2的薄有机-无机混合涂层的这种含锌的金属基底,提供足够的暂时的腐蚀防护,能够在工业组装和形成程序中加工,并且用于在工业金属表面后处理如卷材涂布、车身涂漆线、白色家电和电子设备外壳生产中把多层涂层施加到所述基底。
表1公开了根据本发明的处理溶液的优选实施方案。对于磷化领域的技术人员来说,显然用于所述处理溶液的配方的优选化合物经历了不同的化学反应,因而不应当理解为可分析检测到的处理溶液的成分。
优选的螯合聚(乙烯基苯酚)化合物是聚(5-乙烯基-2-羟基-N-苄基-N-葡糖胺),其如US 5298289中详细描述,是经由组分N-甲基-葡糖胺、甲醛和聚(4-乙烯基苯酚)的门尼希型反应合成的。成膜的水分散性聚合物(F)和蜡化合物(G)分别由商品(Rohm和Haas Co.)和(Noveon Inc.)代表。所有组合物(1-3)揭示了无机组分与聚合树脂的充分的相容性并且证明在高达45℃的温度下高度稳定。
经由辊筒法把根据表1的处理溶液施加到不同镀锌钢金属薄板如和HDG(表2)上,此后在某一峰值金属温度(PMT)下干燥。对于基底,形成均匀混合涂层所需的PMT为至少65℃,而其它镀锌钢基底不得不在100℃的PMT下干燥。取决于组合物以及取决于直接在辊筒施加之后附着到金属薄板上的处理溶液的湿膜厚度,已经实现了比膜重量(FW)在0.6和0.9g/m2之间的不同涂层。
利用标准化的中性盐雾试验(NSST,ASTM B 117-03),根据本发明的优选实施方案处理过的镀锌钢金属薄板由它们的耐蚀性能表征。揭示了涂有根据本发明的处理溶液的所有基底优异的腐蚀性质,在72小时中性盐雾试验之后的白锈覆盖率至少小于5%。
在约0.7g/m2的低膜重量下,在涂层负载有1.2kg的探针重量的同时,利用4点探针技术(Loresta-EP,DIA Instruments Co.,Ltd.)测量的混合涂层的表面电阻(SR)小于1mΩ,因而满足了用于为了电磁场的屏蔽而设计的产品外壳中使用的材料所需的IBM标准(IBMSG-PR-000857)。
根据这些本发明的实施方案,施加到含锌的金属基底时处理溶液产生薄有机-无机混合涂层,当用于产生优异的暂时耐蚀性能的原位干燥方法时,其提供金属基底的均匀覆盖。
另外,根据本发明处理过的金属材料展示出低表面电阻并且能够用作电子设备外壳或白色家电生产中的零件,而有效地保护设备免受电磁感应的破坏。
所述处理溶液本身证明对于离析和/或沉淀是高度稳定的,这改善了涂布过程的可靠性并且降低了与溶液性能的控制和再生循环数有关的成本。
Claims (16)
1.一种用于薄有机/无机混合涂层在含锌的金属表面上的沉积的处理溶液,该处理溶液包含水和
(i)至少0.5重量%的磷酸A;
(ii)一定浓度的溶解的无机组分B,该无机组分B包含至少一种选自钛、锆、铪和/或硅的络合的氟金属化物阴离子,其中所述包含络合的氟金属化物阴离子的溶解的无机组分B的总当量氢浓度与所述磷酸A的当量氢浓度的摩尔比B∶A为至少0.1;
(iii)溶解的无机组分C,其中所述溶液中的由溶解的无机化合物C提供的二价阳离子的总质量份数为至少0.2重量%,该无机组分C由锌的二价阳离子C1组成或由锌的二价阳离子C1和锰的二价阳离子C2组成;
(iv)一定浓度的溶解的无机组分D,该无机组分D由钼的含氧阴离子组成,其中所述由钼的含氧阴离子组成的溶解的无机组分D与锌的二价阳离子C1的摩尔比D∶C1为至少1∶50;
(v)一定浓度的水溶性和/或水分散性聚合物E,该水溶性和/或水分散性聚合物E由一定数量n的x-(N-R1-N-R2-氨甲基)-4-羟基-苯乙烯单体单元组成,其中x=2,3,5或6,表示取代位置序号,R1表示包含1至4个碳原子的烷基,而R2表示符合通式H(CHOH)mCH2-的取代基,其中m是3至5的整数,该水溶性和/或水分散性聚合物E能够螯合所述溶解的无机组分B和/或C;
(vi)水溶性和/或水分散性聚合树脂F,其中处理溶液中的水溶性和/或水分散性聚合树脂(F)的质量份数为至少5重量%,该水溶性和/或水分散性聚合树脂F不是所述水溶性和/或水分散性聚合物E的部分或者与所述水溶性和/或水分散性聚合物E不同,
其中所述锌的二价阳离子C1与所述水溶性和/或水分散性聚合物的螯合部分的摩尔比C1∶n·E不大于化学计量比,但是为至少0.34,n·E为所述水溶性和/或水分散性聚合物E的单体单元的数量n。
2.根据权利要求1的处理溶液,其在高达至少30℃但是不大于45℃的温度下提供防止溶解的、分散的或既溶解又分散的所述水溶性和/或水分散性聚合树脂F的离析的稳定性,其特征在于,所述处理溶液的组分的摩尔浓度遵守下列特定的摩尔比:
(i)所述包含络合的氟金属化物阴离子的溶解的无机组分B的总当量氢浓度与所述磷酸A的当量氢浓度的摩尔比B∶A为至少0.3,但是不大于0.6;
(ii)所述包含络合的氟金属化物阴离子的溶解的无机组分B与所述锌的二价阳离子C1的摩尔比B∶C1为至少2.0,但是不大于3.5,和/或所述包含络合的氟金属化物阴离子的溶解的无机组分B与所述锰的二价阳离子C2的摩尔比B∶C2为至少1.2,但是不大于2.4;
(iii)所述由钼的含氧阴离子组成的溶解的无机组分D与所述锌的二价阳离子C1的摩尔比D∶C1为至少1∶50,但是不大于1∶20,或者所述由钼的含氧阴离子组成的溶解的无机组分D与所述锰的二价阳离子C2的摩尔比D∶C2为至少1∶80,但是不大于1∶20。
3.根据前述权利要求中一项的处理溶液,其特征在于,存在锌的二价阳离子C1,并且所述锌的二价阳离子C1与所述水溶性和/或水分散性聚合物的螯合部分的摩尔比C1∶n·E不大于0.75,其中n·E为所述水溶性和/或水分散性聚合物E的单体单元的数量n。
4.根据权利要求1的处理溶液,其特征在于,所述溶液中的磷酸A的质量份数为至少1.0重量%,但是不大于3.0重量%。
5.根据权利要求1的处理溶液,其特征在于,所述溶液中的由溶解的无机组分C提供的二价阳离子的总质量份数为至少0.4重量%,但是不大于1.2重量%。
6.根据权利要求1的处理溶液,其特征在于,处理溶液中的水溶性和/或水分散性聚合树脂F的质量份数为至少15重量%,但是不大于50重量%。
7.根据权利要求1的处理溶液,其特征在于,所述水溶性和/或水分散性聚合树脂F具有不高于80℃的成膜温度。
8.根据权利要求1的处理溶液,其中所述溶液另外包含稳定分散的固体材料G,该固体材料G以分离的形式时具有不大于0.35的静摩擦系数,该静摩擦系数是在所述固体材料本身和冷轧钢之间测量的,其中所述固体材料G与所述水溶性和/或水分散性聚合树脂F的质量比为至少0.01,但是不大于1。
9.根据权利要求8的处理溶液,其中所述固体材料基于氧化的聚乙烯蜡。
10.根据权利要求1的处理溶液,其特征在于,施加到含锌的金属表面上时,所述处理溶液形成膜重量为至少0.4g/m2,但是不大于1.6g/m2的有机/无机混合涂层。
11.根据权利要求1的处理溶液,其特征在于,在至少50℃的峰值金属温度下干燥的同时,施加到含锌的金属表面上的所述处理溶液形成有机/无机混合涂层。
12.一种含锌的金属表面的处理方法,其特征在于,把根据权利要求1的处理溶液施加到含锌的金属表面上,于是在表面转化和挥发性化合物蒸发之后,形成了膜重量为至少0.4g/m2,但是不大于1.6g/m2的薄有机/无机混合涂层。
13.根据权利要求12的方法,其特征在于,在施加到含锌的金属表面上的处理溶液干燥的同时,峰值金属温度不大于150℃,但是为至少65℃。
14.一种根据权利要求12或13的方法获得的含锌的金属基底,该含锌的金属基底具有薄有机/无机混合涂层,并且所述涂层的膜重量为至少0.4g/m2,但是不大于1.6g/m2。
15.一种根据权利要求14的含锌的金属基底,其中根据工业标准IBM SG-PR-000857利用4点电阻测量法测定的所述基底的表面电阻不大于1.5mΩ。
16.根据权利要求14所述的具有薄有机/无机混合涂层的含锌的金属基底用于在工业金属表面后处理中把多层涂层施加到所述基底的方法的用途。
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