CN104024475B - 转化涂料组合物、经表面处理的钢板以及其制备方法 - Google Patents

转化涂料组合物、经表面处理的钢板以及其制备方法 Download PDF

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CN104024475B
CN104024475B CN201280064022.3A CN201280064022A CN104024475B CN 104024475 B CN104024475 B CN 104024475B CN 201280064022 A CN201280064022 A CN 201280064022A CN 104024475 B CN104024475 B CN 104024475B
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film
steel plate
melanism
organic
surface treated
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CN104024475A (zh
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金演镐
郭荣镇
宋渊均
崔良镐
金兑烨
高景弼
崔昶熏
金钟常
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Posco Holdings Inc
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Abstract

本发明提供一种转化涂料组合物,其包含:0.01wt%至0.2wt%的磷(P);0.01wt%至0.2wt%的镁(Mg);0.005wt%至0.15wt%的锆(Zr);0.005wt%至0.15wt%的钛(Ti);0.005wt%至0.15wt%的钒(V);0.05wt%至1wt%的酚醛树脂;余量的水以及其他不可避免的杂质。还提供一种经表面处理的钢板,其包含基底钢板;在基底钢板上形成的锌或锌合金镀层;在锌或锌合金镀层上形成的黑化层;以及在黑化层上形成的有机和无机复合转化涂层,其中有机和无机复合转化涂层可满足以下重量比:P:Mg:Zr:Ti:V=1:0.045‑2:0.035‑1.5:0.035‑1.3:0.035‑1.5(基于P的重量计)。还提供了一种制备经转化涂料组合物处理的钢板的方法。

Description

转化涂料组合物、经表面处理的钢板以及其制备方法
技术领域
本发明涉及经表面处理的钢板,其应用于家用电器的显示器、家用器具、音频设备、办公(OA)设备等,并且涉及其制备方法。
背景技术
在经表面处理的钢板中,黑钢板是通过黑化处理在其表面形成无机黑色涂层的有色钢板。由于黑钢板能使用户免除涂装过程,其可降低制造成本,并且还由于其黑色表面外观的均匀且相当地具有吸引力,黑钢板广泛应用于各种领域,例如家用器具、音频设备、OA设备以及车辆部件。镀锌钢板的黑化处理主要通过蚀刻法、阴极电解法、阳极电解法等进行,并且无机黑化涂层具有形成在其表面的微裂纹或微孔并且呈化学形式,例如无机化合物(如金属氧化物、金属氢氧化物,或金属),特别是以金属氧化物的形式。无机黑化涂层带有黑色的机理解释为:由于微孔引起的入射光的无规反射,和取决于金属氧化物的可见光的吸收特性。
这样的黑钢板已经通过将锌合金镀层钢板(主要为Zn-Ni合金镀层钢板)经氧化、阳极处理或转化处理形成黑色涂层的方法而制备。
作为代表性的实例,专利文献1和2公开了采用包含金属离子(例如Ni、Co、Fe、Al、Mg、Cu、Sn、C、Cr、Mo、Ag等)的酸性水溶液氧化而在锌合金镀层钢板上形成黑色涂层的方法。此外,专利文献3和4公开了通过在水溶液中对普通钢板或经表面处理的钢板进行阳极处理而形成黑色涂层的方法。专利文献5和6公开了通过在含有金属离子的溶液中对锌或锌合金镀层处理钢板进行转化处理而形成黑色涂层的方法。
直至二十世纪九十年代,主要开发了使用阳极电解、阴极电解、转化处理等的黑化处理方法,但近年来,技术的发展已经以新增或增强物理性能(例如,可加工性、耐腐蚀性、表面外观等)为目标。专利文献7和8解释了黑钢板的热吸收和发射性能、电导、电磁波屏蔽性能等,该黑钢板经受黑化处理并主要使用具有优异的黑化膜粘合性的Zn-Ni镀层钢板作为基底钢板。然而,这些相关的技术具有以下局限:当黑色涂层通过使用电解方法(例如阳极电解法或阴极电解法)形成时,加工成本上升,并且也具有以下局限:出现严重粉化现象,其中由于粘合力的下降,尽管对锌镀层钢板进行了转化处理,仍使得黑化膜破裂或脱离。
此外,专利文献9公开了通过使用含Sn和Ni或Co化合物的溶液在锌镀层钢板或锌合金镀层钢板上形成黑色膜的方法,但是在通过该方法形成黑化膜的情况下,粉化是严重的并因此降低了黑化膜的粘合性。同样,在如上的转化处理的情况下,由于形成黑化膜的反应速率通常低于电解方法中的反应速率,转化处理不适合与在高速/连续过程中操作的电镀生产线相结合操作,并且与电解方法相比较,转化处理的生产率也很低。此外,专利文献10公开了通过在高温和高湿度环境下重整表面膜来黑化钢板的方法,但是具有的限制在于该方法为连续方法,其需要几十分钟的处理时间。
黑化膜可通过使用阴极电解、阳极电解、氧化、转化处理等氧化表面金属膜或者通过置换沉积不同于基底钢板的金属而形成。由于上述方法降低了黑化膜的耐腐蚀性,进行铬酸盐处理以克服这样的局限,但是Cr控制的执行需要一个实施所述控制的可选物,由此需要适用于不同于常规无Cr黑化膜的黑化膜的转化涂膜。
[专利文献]
(专利文献1)日本专利申请特开公开号1986-291981
(专利文献2)日本专利申请特开公开号1990-282485
(专利文献3)日本专利申请特开公开号1987-263995
(专利文献4)日本专利申请特开公开号1994-346288
(专利文献5)日本专利申请特开公开号1988-161176
(专利文献6)日本专利申请特开公开号1987-290880
(专利文献7)日本专利申请特开公开号2006-264297
(专利文献8)日本专利申请特开公开号2004-250787
(专利文献9)日本专利申请特开公开号1990-093077
(专利文献10)日本专利申请特开公开号1995-143679
发明内容
技术问题
本发明的一方面提供转化涂料组合物、环境友好的经表面处理的钢板,该钢板具有优异的耐腐蚀性、黑化膜粘合性、表面外观(例如,黑度和光泽度)和提高的生产率,并且提供其制备方法。
技术方案
根据本发明的一个方面,提供了一种转化涂料组合物,其包括:0.01wt%至0.2wt%的磷(P);0.01wt%至0.2wt%的镁(Mg);0.005wt%至0.15wt%的锆(Zr);0.005wt%至0.15wt%的钛(Ti);0.005wt%至0.15wt%的钒(V);0.05wt%至1wt%酚醛树脂;余量的水以及其他不可避免的杂质。
根据本发明的另一个方面,提供了一种经表面处理的钢板,包括基底钢板;形成在该基底钢板上的锌或锌合金镀膜;形成在该锌或锌合金镀膜上的黑化膜;形成在该黑化膜上的有机和无机复合转化涂膜,其中该有机和无机复合转化涂膜满足以下重量比:
P:Mg:Zr:Ti:V=1:0.045-2:0.035-1.5:0.035-1.3:0.035-1.5(基于P计)。
根据本发明的另一个方面,提供了一种制备经表面处理的钢板的方法,其包括:制备基底钢板;在该基底钢板上形成锌或锌合金镀膜;在该锌或锌合金镀膜上形成黑化膜;以及在该黑化膜上形成有机和无机复合转化涂膜,其中该有机和无机复合转化涂膜可使用转化涂料溶液通过浸涂或喷涂方法形成,所述转化涂料溶液包含0.01wt%至0.2wt%的P;0.01wt%至0.2wt%的Mg;0.005wt%至0.15wt%的Zr;0.005wt%至0.15wt%的Ti;0.005wt%至0.15wt%的V;0.05wt%至1wt%的酚醛树脂;10wt%以下的添加剂;以及余量的水。
发明的有益效果
根据本发明的一个方面,由于可通过抑制黑化处理过程中产生的粉化现象来防止由在制备黑化膜过程中产生的粉化现象引起的辊污染,从而提高黑化膜的粘合性,因此可进行连续的过程而不用频繁地清洗辊和更换辊,并且在树脂的涂布中、即后处理中的树脂膜的粘合性也可提高。
此外,在本发明中,基底钢板(例如镀膜中含有Zn和至少一种比Zn具有更高离子化趋势的元素的镀层钢板)经黑化,由此与常规的镀Zn钢板相比,能够提高反应性并因此可进行高速的黑化处理从而提高了生产率。
此外,通过在黑化膜上形成有机和无机复合转化涂膜,可提高由两种以上金属/金属氧化物/金属氢氧化物构成的黑化膜的低耐腐蚀性。此外,通过确保转化涂膜的耐腐蚀性,在转化涂膜上形成的保护树脂的自由度被增加并因此可易于保证全部的物理性能(可加工性、耐化学性、光泽度等)。
附图简要说明
本发明的以上和其他的方面、特征和其他优点将由以下详细描述并结合附图得到更清楚的理解,其中:
图1为根据本发明的一个方面的经表面处理的钢板的示意性剖视图;
图2为根据镍含量的经表面处理的钢板的表面外观、粉化和pH的图;
图3为根据锡(Sn)含量的经表面处理的钢板的表面外观、粉化和pH的图;以及
图4为根据柠檬酸含量的经表面处理的钢板的表面外观、粉化和pH的图。
发明的最佳实施方式
本发明的发明人发现黑化膜的化学形式和表面结构是在维持黑化膜的优异的表面外观(黑度)和改善黑化膜的粘合性方面的重要因素,因此发现为此,使用适合的溶液和控制处理工艺条件是重要的。同样,在黑化处理中,发明人发现基底钢板与溶液之间的反应性对于提高生产率而言是重要的,因此发现在基底材料上设计镀膜对于提高反应性的重要性。此外,发明人发现通过反应性有机和无机复合转化涂布处理的膜的形成和结构是重要的,其中能够防止或延缓腐蚀因素渗透的阻挡膜应涂布在整个基底材料的表面而没有任何暴露以便提高黑化膜的较差耐腐蚀性,并从而完成本发明。
下文,将详细描述根据本发明的一个方面的转化涂料组合物。所述转化涂料组合物可包括磷(P)化合物、镁(Mg)化合物、锆(Zr)化合物、钛(Ti)化合物、钒(V)化合物、酚醛树脂、余量的水以及其他不可避免的杂质。
通过P化合物引入的磷酸离子(PO4 3-)在黑化膜上形成磷酸盐。磷酸盐的形成有助于提高黑化膜的耐腐蚀性,并且P化合物可以以普通盐(例如Na盐、K盐等)形式引入,还可以磷酸溶液的形式引入。优选通过P化合物引入的P含量在0.01wt%至0.2wt%的范围内。优选限制P含量不低于0.01wt%以上以便使磷酸盐充分形成在黑化膜上并因此提高耐腐蚀性。由于要考虑耐腐蚀性的提高效果的饱和以及经济性,并且过量加入P引起沉淀,这是由于与另一组分形成化合物降低了溶液的稳定性,因此,优选P含量限制在不超过0.2wt%。
通过引入Mg化合物,在转化涂膜中形成氧化镁(氢氧化镁)。氧化镁(氢氧化镁)有助于提高黑化膜的耐腐蚀性,并且Mg化合物可以与F-、Cl-、OH-、NO3 -、SO4 2-、CO3 2-、ClO4 -或PO4 3-的无机盐的形式引入,或以与有机酸(例如,乙酸等)的离子的盐的形式引入。优选通过Mg化合物引入的Mg含量在0.01wt%至0.2wt%的范围内。为确保足够的耐腐蚀性,优选限制Mg含量不低于0.01wt%。由于要考虑耐腐蚀性的提高效果的饱和以及经济性,并且过量加入Mg会增加膜中的自由离子从而降低耐腐蚀性,因此,优选Mg含量限制在不超过0.2wt%。
通过引入Zr化合物、Ti化合物和V化合物,形成绝缘氧化物膜。该绝缘氧化物膜有助于提高黑化膜的耐腐蚀性,并且Zr化合物、Ti化合物和V化合物可以与F-、Cl-、OH-、SO4 2-的络合物或盐的形式和有机氧化物(例如,有机丁氧化物、有机丙氧化物、有机酮等)的形式引入,或者以氧化物(例如MOn(M:Zr、Ti、V))的络合物或盐的形式引入。优选通过金属化合物引入的金属的含量在0.005wt%至0.15wt%的范围内。为通过充分形成绝缘氧化物来确保耐腐蚀性,优选限制金属含量不低于0.005wt%。另一方面,由于要考虑耐腐蚀性的提高效果的饱和以及和经济性,并且过量加入金属会增加膜中的自由离子从而降低耐腐蚀性,因此,优选金属含量限制在不超过0.15wt%。
酚醛树脂使金属组分分散在溶液中以稳定溶液并形成有机和无机复合膜以增加转化涂膜的致密性,并由此有助于提高耐腐蚀性。优选本发明的酚醛树脂包含胺基团或一个或多个卤素元素(F、Cl、Br和I)官能基团以便提高与金属的亲合性,并具有以下化学式:
在酚醛树脂的结构中,作为A官能基团,一个或多个选自伯胺、仲胺、叔胺和季胺基团的胺基团可与酚环上的一个或多个碳原子结合,并且一个或多个卤素元素可结合在聚合物链的中部或端部的酚环上。酚醛树脂可以单一聚合物或共聚物以及与其他聚合物的混合物的形式使用。优选酚醛树脂的含量在0.05wt%至1wt%的范围内。为确保耐腐蚀性和有助于溶液的稳定,优选限制酚醛树脂含量不低于0.05wt%。然而,由于要考虑耐腐蚀性的提高效果的饱和以及经济性,并且过量加入酚醛树脂可增加溶液的粘度而使进行浸涂型或喷涂型的转化涂布变得困难,因此,优选酚醛树脂含量限制在不超过1wt%。
作为添加剂,还可添加消泡剂、中和剂等。加入消泡剂以除去泡沫,加入中和剂以维持溶液的pH,并且消泡剂和中和剂即使为常规可得的产品,它们仍具有足够的效果。然而,优选添加剂的含量不超过10%。原因是由于过量加入的添加剂将增加溶液的粘度并且不经济。
在根据本发明的一个方面的转化涂料组合物中,余量是水。然而,由于在通常的制备过程中从原料或周边环境不可避免地加入不期望的杂质,因此这些不可避免的杂质不可排除。由于这些杂质对本领域技术人员是公知的,在本说明书中不具体提及其含量。
下文,将详细描述根据本发明的另一个方面的经表面处理的钢板。经表面处理的钢板包括基底钢板、在该基底钢板上形成的锌或锌合金镀膜、在该锌或锌合金镀膜上形成的黑化膜,以及在该黑化膜上形成的有机和无机转化涂膜。
在本发明中,基底钢板并不特别限制,并且使用的任何基底钢板对本发明没有影响。
在基底钢板上形成锌或锌合金镀膜中,所述镀膜可以是锌镀膜且可包含一种或多种比Zn具有更高离子化趋势的元素以实现本发明期望的生产率的提高。组分体系得以控制的原因与形成在镀膜上的黑化膜密切相关。为形成黑化膜,使用基于以下化学反应的黑化液:包含在黑化液中的比Zn贵重的金属离子通过置换Zn而沉淀。具有比Zn更高离子化趋势的元素展示出比Zn更快的置换和沉淀反应,并且Zn和这种元素的合金镀层钢板示出比纯Zn镀层钢板快得多的黑化反应速率,这导致生产率的提高。具有比Zn更高离子化趋势的元素的实例通常可包括但并不限于Mg、Al等。熔融电镀和干法涂布(例如,物理气相沉积(PVD))可被用于制造镀膜包含Zn和具有比Zn更高离子化趋势的元素的电镀钢板。
此外,尽管对电镀元素的含量没有限制,但为了提高生产率,有必要控制组成元素的组分比例。由于黑化活性随具有比Zn更高离子化趋势的元素的含量变化,因此优选该元素的含量控制在2原子%至55原子%。为提高反应性和黑化速度,优选限制具有比Zn更高离子化趋势的元素的含量不低于2原子%。然而,在该含量过量的情况下,会发生过量的反应,致使黑化膜的粘合性降低,不能获得均匀的黑度,经济性会降低,因此优选限制具有比Zn更高离子化趋势的元素的含量不超过55原子%。
此外,在经表面处理的钢板中,可在镀膜上形成黑化膜。黑化膜的组成和沉淀颗粒的大小对黑化膜的粘合性和黑钢板的表面外观(例如,黑度和光泽度)具有影响。在本发明中,通过置换沉淀和氧化机理形成的黑化膜可以为金属、金属氧化物和金属氢氧化物的混合物状态。如果析出的颗粒太粗糙,会降低黑化膜的粘合性,致使粉化发生。因此,优选限制颗粒的平均直径的上限为500nm。此外,如果粒径太小,不能获得足够黑的外观。因此,优选限制粒径的下限为50nm。此外,由于粒径决定了黑化膜的厚度,优选黑化膜的厚度在50nm至500nm范围内。
此时,金属可包含一种或多种选自以下的元素:Mg、Al、Zn、Fe、Ni、Co、Mn、Ti、Sn、Sb和Cu并且是决定本发明的经表面处理的钢板的表面外观(黑度和光泽度)的重要因素。此外,黑化膜的组成可满足以下的原子比Zn:M:O=1:0.01-0.065:0.1-0.5(基于Zn计)。此时,M可以是上述金属元素的一种或多种,并且各金属元素可以在0.01-0.065的原子比范围内。如果金属M含量低于所述原子比范围的下限,则表面外观和黑度将劣化,如果金属M含量超过所述原子比范围的上限,则可发生粉化。
在黑化膜上形成有机和无机复合转化涂膜。有机和无机复合转化涂膜可提高经表面处理的钢板的耐腐蚀性。优选通过上述转化涂料溶液形成该有机和无机复合转化涂膜。
优选有机和无机复合转化涂膜的无机组分满足以下的重量比:
P:Mg:Zr:Ti:V=1:0.045-2:0.035-1.5:0.035-1.3:0.035-1.5(基于P的重量计)。原因为如果各组分的重量比低于该下限,不足以形成转化涂膜并因此对耐腐蚀性没有什么贡献,如果各组分的重量比超过该上限,对耐腐蚀性的贡献没有较大差别并且是不经济的。
在根据本发明的一方面的经表面处理的钢板中,对有机和无机复合转化涂膜的厚度并不特别限制。由于厚度的增加将提高耐腐蚀性但降低生产率,因此考虑耐腐蚀性和生产率应适当控制有机和无机复合转化涂膜的厚度。
此外,经表面处理的钢板在有机和无机复合转化涂膜上还可包含树脂膜。树脂模可以是单层膜或多层膜。树脂膜作为黑钢板的保护涂层形成。树脂的类型并不特别限制,但是优选树脂膜包括选自以下的一种或多种:聚氨酯树脂、聚丙烯酸树脂(polyacryl resin)、环氧树脂、苯氧树脂,和聚酯树脂。为形成树脂膜,可利用水溶类型或溶剂溶类型的上述树脂。
图1为根据本发明的一个方面的经表面处理的钢板的示意性剖视图。在基底钢板1上形成镀膜2、在镀膜2上形成黑化膜3,在黑化膜3上形成有机和无机复合转化涂膜4以及在有机和无机复合转化涂膜4上形成树脂膜5。
下文,将详细描述根据本发明的另一个方面的制备经表面处理的钢板的方法。制备经表面处理的钢板的方法包括:制备基底钢板;在该基底钢板上形成锌或锌合金镀膜;在该锌或锌合金镀膜上形成黑化膜;以及在该黑化膜上形成有机和无机复合转化涂膜,其中该有机和无机复合转化涂膜可使用转化涂料溶液通过浸涂或喷涂方法形成,所述转化涂料溶液包含0.01wt%至0.2wt%的P;0.01wt%至0.2wt%的Mg;0.005wt%至0.15wt%的Zr;0.005wt%至0.15wt%的Ti;0.005wt%至0.15wt%的V;0.05wt%至1wt%的酚醛树脂;10wt%以下的添加剂;以及余量的水。
首先,制备基底钢板。如上所述,基底钢板并不特别限制。
在所制备的基底钢板上形成锌或锌合金镀膜。虽然纯Zn镀层钢板可用作镀膜,但优选镀膜包括Zn和上述一种或多种比Zn具有更高离子化趋势的元素。此时,很难通过常规电镀法来合金-电镀高浓度的具有比Zn更高离子化趋势的元素。因此,优选通过使用干法涂布(例如,PVD)或熔融锌镀法而不是电镀法形成镀膜。
其次,在镀膜上形成黑化膜。黑化液将在下文描述。黑化膜可通过黑化液的转化涂布(例如浸涂、喷涂等)而形成。
黑化液可包含有机酸、无机酸离子、表面改性剂以及余量的水。黑化液的成分与黑化膜的组成、化学结构和表面结构密切相关,因此适当地设计黑化液的组成和设定含量范围是必要的。
金属离子包括选自以下的一种或多种:Mg、Al、Zn、Fe、Ni、Co、Mn和Ti,优选控制该金属离子的含量在100mmol/L至1500mmol/L范围内。此外,金属离子包括选自以下的一种或多种:Sn、Sb和Cu,优选控制该金属离子的含量在10mmol/L至50mmol/L范围内。通过将金属离子含量控制在所述范围内,可提高黑钢板的表面外观和黑度,并且考虑经济性可限制各组分的上限。优选限制Sn、Sb和Cu的含量不超过50mmol/L以防止粉化。
此外,黑化液可包含有机酸。包含有机酸作为溶液稳定剂(即,络合剂)并确保均匀的表面外观。优选地,包括2g/L以上的有机酸以提高络合力、防止金属离子的沉淀以及稳定溶液。此外,如果有机酸超过60g/L,过量形成与金属离子的络合物,阻碍了金属氧化物的沉淀,这导致了差的表面外观(黑度)。优选地,有机酸可包括选自以下的一种或多种:乙酸、柠檬酸、酒石酸、苹果酸、草酸、邻苯二甲酸和马来酸。
此外,黑化液可包含无机酸。在黑化过程中加入无机酸以促进氧化并确保溶液的稳定。优选加入无机酸以控制黑化液的pH在l.0-4.0的范围内。由于强氧化能力可溶解镀膜而不是形成黑化膜,因此优选包含无机酸以控制黑化液的pH不小于l.0。当氧化力过低时,反应性会削弱,并且金属离子可水解以产生沉淀,由此降低了溶液的稳定性。因此,优选包含无机酸以控制黑化液的pH不大于4.0。优选地,无机酸可包含选自以下的一种或多种:NO3 -、SO4 2-、PO4 3-、Cl-、ClO3 -和ClO4 -
此外,黑化液可包含表面改性剂。表面改性剂可控制黑化膜中沉淀颗粒的组成和大小。根据表面改性剂的类型来控制表面改性剂含量的不同,但是优选限制通过使用表面改性剂沉淀出的黑化颗粒的大小不超过500nm。还优选表面改性剂包含选自以下的一种或多种:胺络合剂、多胺络合剂(polyamine complex agent)、多羟基化合物络合剂(polyolcomplex agent)、多元醇络合剂(polyalcohol complex agent)以及氧化剂。
在根据本发明的一方面的黑化液中,余量是水。然而,由于在通常的制备过程中从原料或周边环境可不可避免地加入不期望的杂质,因此这些不可避免的杂质不可排除。由于这些杂质对本领域技术人员是公知的,在本说明书中不具体提及其含量。
在黑化膜上形成有机和无机复合转化涂膜。转化涂膜可作为单层膜或多层膜形成。同样,如上所述,优选有机和无机复合转化涂膜通过常规的转化涂布法例如浸涂法或喷涂法形成。
此外,还可在有机和无机复合转化涂膜上形成树脂膜。形成树脂膜的方法并不特别限制,可使用能形成树脂膜的任何方法。树脂膜可作为单层膜或多层膜形成,并且即使形成为多层树脂膜,其制备方法并不特别限制。
下文,将参照实施例更详细描述本发明。应注意以下实施例不应被解释为对本发明范围的限制,而是仅示例性地提供对本发明更详细的描述。因此,本发明的范围通过以下权利要求书中所述的主题和由其合理类推的主题而确定。
(实施例)
选择Zn和另一种具有比Zn更高离子化趋势的Mg元素,并且如表1中所示控制其含量比。通过干法涂布(例如,PVD)制备Zn-Mg镀层钢板,其中镀膜的涂布量控制在10g/m2。在40℃下将Zn-Mg镀层钢板浸入具有本发明提出的组分比例的黑化液中2秒以在Zn-Mg镀层钢板上形成黑化膜。
测量由以上制备方法制备的经表面处理的钢板的表面外观(白度)、光泽度以及粉化,并且将测量结果示于以下表1中。
表面外观,即,白度(L*)通过色差计测量,并且随着所测量的白度值接近零,黑度增加。同样,当将透明胶带的粘合表面有力地粘在黑化膜上然后分离该透明胶带时,通过观察由粘合表面所分离的黑化颗粒(即,粉末)进行粉化评价。为量化粉化的特性,通过使用色差计测量粉化部分的白度(Lp)。这意指随着测量值接近89(其为不经受胶带实验的样品的Lp值),粉化的发生降低。使用光泽计在60度的入射角下测量光泽度。
表1
如表1所示,可确定,满足本发明的镀膜组分比的本发明实施例1-4不具有任何表面外观(黑度)和粉化的问题,并具有优异的光泽度。同样,可确定,处理速度比纯Zn处理的钢板的处理速度提高2倍以上。
另一方面,由于对比实施例1和2中的Mg含量大于本发明所控制的Mg含量,可确定由于过度的反应,黑化膜的粘合性降低。由于对比实施例3中的Mg含量少于本发明所控制的Mg含量,可确定反应性下降,因此黑化速度非常低,而且黑度不好。
(实施例2)
在40℃下将作为基底钢板的Zn-Mg合金镀层钢板(Zn:Mg(原子%)=60:40,镀膜量10g/m2)浸入黑化液中2秒以形成黑化膜。该黑化液包含Ni和Sn作为金属离子,并且还包含柠檬酸、硫酸以及表面改性剂作为添加剂。
(1)使用包含25mmol/L Sn、10g/L柠檬酸、2g/L硫酸以及1g/L表面改性剂的黑化液,并且Ni含量控制在50mmol/L至1022mmol/L的范围内。评价取决于Ni含量的黑钢板的表面外观(L*)以及粉化部分的白度(Lp)和pH,并在表2中示出。评价方法与实施例1中相同。
如表2所示,当Ni含量在100mmol/L至1500mmol/L的范围内时,表面外观、粉化和pH满足本发明想要的范围。通过维持适合的pH范围,可确定确保了溶液稳定而没有沉淀或漂浮物。
(2)使用包含500mmol/L Ni、10g/L柠檬酸、2g/L硫酸以及1g/L表面改性剂的黑化液,并且Sn含量控制在1mmol/L至100mmol/L的范围内。评价取决于Ni含量的黑钢板的表面外观(L*)以及粉化部分的白度(Lp)和pH,并在表3中示出。评价方法与实施例1中相同。
如表3所示,当Sn含量在10mmol/L至50mmol/L的范围内,表面外观、粉化和pH满足本发明想要的范围。通过维持适合的pH范围,可确定确保了溶液稳定而没有沉淀或漂浮物。
(3)使用包含500mmol/L Ni、25mmol/L Sn、2g/L硫酸以及1g/L表面改性剂的黑化液,并且柠檬酸含量控制1mmol/L至100mmol/L的范围内。评价取决于柠檬酸含量的黑钢板的表面外观(L*)以及粉化部分的白度(Lp)和pH,并在表4中示出。评价方法与实施例1中相同。
如表4所示,当柠檬酸含量在2g/L至60g/L的范围内时,表面外观、粉化和pH满足本发明想要的范围。通过维持适合的pH范围,可确定确保了溶液稳定而没有沉淀或漂浮物。
(4)使用包含500mmol/L Ni、25mmol/L Sn、10g/L柠檬酸、2g/L硫酸的黑化液、以及还包含1g/L表面改性剂的黑化液,评价表面外观(L*)以及粉化。评价方法与实施例1中相同。
无论是否添加表面改性剂,表面外观(L*)展示出优异的黑度,但是当不加入表面改性剂时,产生严重的粉化,并且可确定黑化膜包括尺寸超过500nm的粗糙颗粒。同样,可确定当加入表面改性剂时,在黑化膜中的沉淀颗粒具有小于500nm的尺寸并且不产生粉化。
(实施例3)
在40℃下将作为基底钢板的Zn-Mg合金镀层钢板(Zn:Mg(原子%)=60:40,镀膜量10g/m2)浸入黑化液(500mmol/L Ni、25mmol/L Sn、10g/L柠檬酸、2g/L硫酸以及1g/L表面改性剂)中2秒以形成黑化膜。随后,形成有黑化膜的Zn-Mg合金镀层钢板浸入具有如表2所示的组成的转化涂料溶液中以在黑化膜上形成有机和无机复合转化涂膜,然后涂布2μm厚的聚氨酯保护树脂,并评价耐腐蚀性。通过根据JIS E2731标准的盐雾试验(SST)进行耐腐蚀性测试,并在72小时后,目测确定白锈的产生并在表2中示出。没有白锈产生用"O"表示,少于5%的白锈产生用"Δ"表示,不少于5%的白锈产生用"X"表示。
表2
如表2中所示,可确定满足本发明所控制的有机和无机复合转化涂料溶液的组分比例的本发明实施例5-11在72小时的SST中具有的耐腐蚀性小于5%并且转化涂膜具有以下组分比例:
P:Mg:Zr:Ti:V=1:0.045-2:0.035-1.5:0.035-1.3:0.035-1.5(基于P的重量比)。
另一方面,可确定由于对比实施例5-8具有的溶液中的各元素含量小于本发明所控制的元素含量,因此未充分形成转化涂膜,从而耐腐蚀性降低。同样,可确定由于对比实施例9和10具有的Mg、Zr、Ti和V的含量超过本发明所控制的含量,因此耐腐蚀性降低。
[附图中的标号说明]
1:基底钢板
2:镀膜
3:黑化膜
4:有机和无机转化涂膜
5:树脂膜

Claims (22)

1.一种转化涂料组合物,其包含:0.01wt%至0.2wt%的磷(P);0.01wt%至0.2wt%的镁(Mg);0.005wt%至0.15wt%的锆(Zr);0.005wt%至0.15wt%的钛(Ti);0.005wt%至0.15wt%的钒(V);0.05wt%至1wt%的酚醛树脂;余量的水以及其他不可避免的杂质。
2.权利要求1的转化涂料组合物,还包含不超过10wt%的消泡剂和中和剂中的至少一种。
3.权利要求1的转化涂料组合物,其中所述酚醛树脂包含胺基团或一种或多种卤素元素官能团。
4.权利要求1的转化涂料组合物,其中所述酚醛树脂包含胺基团或一种或多种选自F、Cl、Br和I的官能团。
5.权利要求1的转化涂料组合物,其中所述酚醛树脂包含一种或多种选自以下的胺基团:与一个或多个碳原子结合的伯胺、仲胺、叔胺和季胺基团,并且一个或多个卤素元素结合在聚合物链的中部或端部。
6.一种经表面处理的钢板,其包括基底钢板;在该基底钢板上形成的锌镀膜或锌合金镀膜;在该锌镀膜或锌合金镀膜上形成的黑化膜;以及在该黑化膜上形成的有机和无机复合转化涂膜,其中该有机和无机复合转化涂膜满足以下重量比:
P:Mg:Zr:Ti:V=1:0.045-2:0.035-1.5:0.035-1.3:0.035-1.5(基于P计)。
7.权利要求6的经表面处理的钢板,其中所述镀膜为1)Zn镀膜或2)包含Zn和一种具有比Zn更高离子化趋势的元素的镀膜。
8.权利要求7的经表面处理的钢板,其中所述具有更高离子化趋势的元素的含量为2至55原子%。
9.权利要求6的经表面处理的钢板,其中所述黑化膜满足的原子比为Zn:M:O=1:0.01-0.065:0.1-0.5(基于Zn的原子比计),其中M是一种或多种选自以下的元素:Mg、Al、Zn、Fe、Ni、Co、Mn、Ti、Sn、Sb和Cu。
10.权利要求6的经表面处理的钢板,其中所述黑化膜的厚度为50nm至500nm。
11.权利要求6的经表面处理的钢板,其中在所述黑化膜中沉淀的金属氧化物颗粒具有50nm至500nm的平均直径。
12.权利要求6的经表面处理的钢板,还包括在所述有机和无机复合转化涂膜上的树脂膜。
13.权利要求12的经表面处理的钢板,其中所述树脂膜包括选自以下的一种或多种:聚氨酯树脂、聚丙烯酸树脂、环氧树脂、苯氧树脂,和聚酯树脂。
14.一种制备经表面处理的钢板的方法,其包括:
制备基底钢板;在该基底钢板上形成锌镀膜或锌合金镀膜;在该锌镀膜或锌合金镀膜上形成黑化膜;以及在该黑化膜上形成有机和无机复合转化涂膜,其中该有机和无机复合转化涂膜使用一种转化涂料溶液通过浸涂法或喷涂法而形成,所述转化涂料溶液包含0.01wt%至0.2wt%的P;0.01wt%至0.2wt%的Mg;0.005wt%至0.15wt%的Zr;0.005wt%至0.15wt%的Ti;0.005wt%至0.15wt%的V;0.05wt%至1wt%的酚醛树脂;10wt%以下的添加剂;以及余量的水。
15.权利要求14的方法,其中所述黑化膜通过使用黑化液形成,所述黑化液包含金属离子、有机酸、无机酸离子、表面改性剂以及余量的水。
16.权利要求15的方法,其中所述金属离子包含100mmol/L至1500mmol/L的一种或多种选自以下的金属离子:Mg、Al、Zn、Fe、Ni、Co、Mn和Ti;以及10mmol/L至50mmol/L的一种或多种选自以下的金属离子:Sn、Sb和Cu。
17.权利要求15的方法,其中所述有机酸包括选自以下的一种或多种:乙酸、柠檬酸、酒石酸、苹果酸、草酸、邻苯二甲酸和马来酸,并且所述有机酸的含量为2-60g/L。
18.权利要求15的方法,其中所述无机酸离子包括选自以下的一种或多种:NO3 -、SO4 2-、PO4 3-、Cl-、ClO3 -和ClO4 -,以使所述黑化液的pH在l.0-4.0的范围内。
19.权利要求15的方法,其中所述表面改性剂包括选自以下的一种或多种:胺络合剂、多羟基化合物络合剂以及氧化剂。
20.权利要求15的方法,其中所述表面改性剂包括选自以下的一种或多种:多胺络合剂、多元醇络合剂以及氧化剂。
21.权利要求14的方法,其中所述黑化液的pH在l.0-4.0的范围内。
22.权利要求14的方法,在形成所述有机和无机复合转化涂膜之后,还在该有机和无机复合转化涂膜上形成树脂膜。
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CN104024475A (zh) 2014-09-03
US20150218705A1 (en) 2015-08-06
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