EP2106425A2

EP2106425A2 - Conductive, organic coatings with low layer thickness and good plasticity

Info

Publication number: EP2106425A2
Application number: EP07857253A
Authority: EP
Inventors: Eva Wilke; Manuela GÖSKE-KRAJNC; Reiner Wark; Guadalupe Sanchis Otero; Stephan Müller; Marcel Roth; Wolfgang Lorenz; Karsten Hackbarth; Andreas Kunz
Original assignee: Henkel AG and Co KGaA
Current assignee: Henkel AG and Co KGaA
Priority date: 2007-01-04
Filing date: 2007-12-05
Publication date: 2009-10-07
Also published as: JP2010514599A; US20090324938A1; WO2008080746A3; CA2674338A1; US7919181B2; DE102007001653A1; JP5094876B2; TW200840884A; MX2009006572A; WO2008080746A2; KR20090122194A

Abstract

The invention relates to a metal sheet, or a component made of a metallic material, comprising a layer system on the surface with at least the following layers: a) a conversion layer, comprising no more than 1 mg chromium per m2, b) a layer of a cross-linked organic polymer system with a thickness in the range of 0.5 to 2.5 µm, comprising, in relation to the total mass of said layer, 2 to 25 wt.% of an electrically conductive pigment having a specific weight of 3 g/cm3 maximum, however no more than 5 wt. % of the electrically conductive pigment having a specific weight of more than 3 g/m3. A coating material and a coating method for the production of the layer b).

Description

"Conductive, organic coatings with low layer thickness and good

formability "

The present invention relates to conductive and weldable anticorrosive coatings of metal surfaces and to a method of coating metal surfaces with electrically conductive organic coatings. The layer thickness is in the range of 0.5 to 2.5 microns. It further relates to a method for producing molded components from metal sheets coated in this way.

As electrically conductive in the context of the invention, a coating is to be understood, which is weldable after curing under the usual conditions of the joining technique in the automotive industry, preferably by the spot welding method. Furthermore, the conductivity should be sufficient to ensure complete deposition of these paints under the usual deposition conditions of electrodeposition paints.

In the metalworking industry, especially in the construction of motor vehicles, the metallic components of the products must be protected from corrosion. According to the conventional state of the art, the sheets in the rolling mill are first coated with anticorrosive oils and optionally coated with drawing fats prior to deformation and punching. In the automotive industry, correspondingly shaped sheet metal parts are punched out for the body or body parts and thermoformed using said drawing fats or oils by deep drawing, then generally joined together by welding and / or crimping and / or gluing and then cleaned consuming. This is followed by the corrosion-protecting surface pretreatments such as phosphating and / or chromating, whereupon a first coating layer is applied to the components by means of electrocoating. This usually follows first electrocoating, especially in the case of automobile karossehen, the application of several other coats of paint.

In the metalworking industry, such as in vehicle and household appliance construction, for reasons of process simplification, there is a desire to reduce the cost of chemical corrosion protection treatment. This can be done by using raw material in the form of metal sheets or metal strips which already carry a corrosion protection layer.

There is therefore a need to find simpler manufacturing methods in which already pre-coated sheets can be formed, welded and electrocoated in a proven manner. Thus, there are a number of processes in which a more or less conductive organic coating is applied following phosphating and / or chromating by the so-called coil coating process. These organic coatings should generally be such that they have sufficient electrical conductivity to not adversely affect automotive-typical welding process, such as electric spot welding process. In addition, these coatings should be coatable with conventional electrodeposition paints.

In particular, in the automotive industry are in addition to normal steel sheets increasingly also galvanized by various methods and / or alloy-galvanized steel sheets used in recent times.

The coating of steel sheets with organic coatings which are weldable and which are applied directly in the rolling mill by the so-called coil coating process is known in principle.

For example, DE-C-3412234 describes a conductive and weldable corrosion protection primer for electrolytically thin-galvanized, phosphated or chromated and deformable sheet steel. This anticorrosion primer consists of a mixture of more than 60% zinc, aluminum, graphite and / or molybdenum disulphide. fid and another anticorrosive pigment and 33 to 35% of an organic binder and about 2% of a dispersing aid or catalyst. As organic binder polyester resins and / or epoxy resins and their derivatives are proposed. It is believed that this technology forms the basis of the coating agent known in the industry as "Bonazinc 2000".

According to the teaching of DE-C-3412234, the organic binder can consist of polyester resins and / or epoxy resins and derivatives thereof. Specifically mentioned are an epoxide / phenyl precondensate, an epoxy ester and linear oil-free mixed polyesters based on terephthalic acid.

EP-A-573015 describes an organically coated steel composite sheet comprising a surface coated on one or both sides with a zinc or zinc alloy provided with a chromate film and an organic coating thereon having a thickness of 0.1 to 5 μm. The organic coating is formed from a primer composition consisting of an organic solvent, an epoxy resin having a molecular weight between 500 and 10,000, an aromatic polyamine and a phenolic or cresol compound as an accelerator. Furthermore, the primer composition contains a polyisocyanate and colloidal silica. According to the teaching of this document, the organic coating is preferably applied in a dry film thickness of 0.6 to 1.6 μm, since thinner layers than 0.1 μm are too thin to effect corrosion protection. Layer thicknesses above 5 μm, however, affect the weldability.

Analogously, DE-A-3640662 describes a surface-treated steel sheet comprising a zinc-coated or zinc-plated steel sheet, a chromate film formed on the surface of the steel sheet and a layer of a resin composition formed on the chromate film. This resin composition consists of a basic resin which is prepared by reacting an epoxy resin with amines, as well as a Polyisocyanate compound. Also, this film may only be applied in dry film thicknesses of less than about 3.5 microns, because at higher film thicknesses, the weldability is greatly reduced.

WO 99/24515 discloses a conductive and weldable anticorrosive composition for coating metal surfaces comprising a) from 10 to 40% by weight of an organic binder containing aa) at least one epoxy resin) at least one hardener selected from guanidine, substituted guanidines, substituted ones Ureas, cyclic tertiary amines and mixtures thereof ac) at least one blocked polyurethane resin b) 0 to 15% by weight of a silicate-based anticorrosion pigment c) 40 to 70% by weight of powdered zinc, aluminum, graphite and / or molybdenum sulfide, carbon black, iron phosphide d) 0 to 30 wt .-% of a solvent contained.

WO 01/85860 relates to a conductive and weldable anti-corrosion composition for coating metal surfaces, characterized in that, based on the total composition, a) from 5 to 40 wt .-% of an organic binder containing aa) at least one epoxy resin ab) at least one Hardener selected from cyanoguanidine,

Benzoguanamine and plasticized urea resin ac) at least one amine adduct selected from

B) 0 to 15% by weight of an anticorrosive pigment c) 40 to 70% by weight of conductive pigment selected from pulverulent zinc, aluminum, graphite, molybdenum sulfide, carbon black and iron phosphide d) 0 to 45% by weight a solvent and, if desired, up to 50% by weight of further active ingredients or auxiliaries, the proportions of the components adding up to 100% by weight.

WO 03/089529 describes a mixture for applying a polymeric, corrosion-resistant, low-wear reshapable and electrically conductive or semiconducting coating which is in particular only up to 6 μm thick to a substrate, the mixture A) containing a content of electrically conductive and / or semiconductive elements. Compounds selected from the group of a) electrically conductive and / or semiconducting particles having a particle size distribution with a d.sub.50 throughput value of <6 .mu.m, b) electrically conductive and / or semiconducting polymeric compounds, and c) electrically conductive or / and semiconducting amine. and / or ammonium-containing compounds and B) at least one binder optionally including reactive diluent (s) and C) in each case at least one crosslinker or / and at least one photoinitiator and D) optionally also in each case at least one component selected from d) postcrosslinking compounds, e ) Additives, f) anti-corrosive pigments, g) corrosion inhibitors which are not present in particulate form and optionally E) organic solvent or / and water, the sum of the weight proportions of all conductive and / or semiconductive elements / compounds A) being from 0.5 to 70% by weight and Content of particles a) 0 to 60 wt .-% is.

Similarly, WO 03/089507 describes a mixture for applying a polymeric, corrosion-resistant, low-wear reshapeable and electrically conductive coating on a substrate, the mixture in addition to at least one substance A in the form of electrically conductive hard particles at least one substance B in the form of very soft or soft, inorganic, lubricious, electrically conductive or semiconductive particles or / and at least one substance C in the form of metallic, soft or hard, electrically conductive or semiconducting particles and / or carbon black and possibly other constituents such as a corrosion protection pigment D included where the sum of the proportions by weight of water-insoluble or sparingly water-soluble pigmentation is X (A + B + C) and where the size of the electrically conductive, harder Particle A is less than 10 μm in relation to the particle size passage value d99.

Finally, WO 03/089530 describes a paint-like mixture containing resin and inorganic particles for applying a polymeric, corrosion-resistant, low-wear, electrically conductive coating to a substrate, wherein the mixture is at least 10% by weight more electrically conductive particles having an electrical conductivity better as particles of zinc and with a Mohs hardness greater than 4 based on the solids content of the mixture and wherein these electrically conductive particles have a particle size distribution, wherein 3 to 22 vol .-% of the electrically conductive particles measured with a Mastersizer 2000 with Measuring head Hydro 2000S from Malvern Instruments in a volume representation are larger than the average layer thickness of the dried and possibly also cured coating determined by scanning electron micrographs.

Despite the extensive state of the art, there remains a need to further improve the known weldable anticorrosion coatings. On the one hand, this concerns the desire for material savings and for weight reduction, which makes the smallest possible layer thickness desirable. On the other hand, despite the smallest possible layer thickness sufficient corrosion protection should be effected. Furthermore, the weldable coatings should have good sliding properties, so that the coated sheets can be formed as possible without oiling. This can be saved on the one hand forming oil and on the other hand, the required cleaning can be simplified before further overcoating. This further reduces material consumption throughout the entire production chain. The object of the present invention is to provide coated metal substrates and a coating process which bring about the stated advantages. Therefore, in a first aspect, the present invention relates to a sheet metal or component of a metallic material having on its surface a layer system comprising at least the following layers: a) a conversion layer containing not more than 1 mg of chromium per m ² , b) a Layer of a crosslinked organic polymer system having a thickness in the range of 0.5 to 2.5 microns, which, based on the total mass of this layer, 2 to 25 wt .-% of an electrically conductive pigment having a specific gravity of not more than 3 g / cm ^3, but does not contain more than 5 wt .-% electrically conductive pigment with a specific weight of more than 3 g / cm ^3.

As is common in the automotive industry, the metallic material may be selected from aluminum or an aluminum alloy, zinc or a zinc alloy, steel or steel coated with zinc, aluminum or alloys of zinc or aluminum.

The conversion layer a), which contains not more than 1 mg / m ^{2 of} chromium, can be carried out by phosphating or chromium-free conversion processes based on acid solutions of complex fluorides of boron, silicon and in particular titanium and / or zirconium. In the latter case, corrosion protection and the adhesion of the subsequently applied layer b) can have a positive effect if the conversion solution for the preparation of the conversion layer a) is admixed with organic resins such as, for example, polyacrylates or amino-substituted polyvinylphenols. Preferably, the conversion layer a) contains less than 0.1 mg of chromium per m ² and is particularly preferably free of chromium. This takes into account the future requirement for chromium-free coated automotive bodies.

In order for a sheet metal or component which carries the abovementioned layers a) and b) to be readily deformable and causes a slight wear of the unforming tools, it is recommended that the layer b) have a Mohs hardness of not more than 4. The organic polymer system of layer b) can have a different structure. For example, the layer b) as a crosslinked organic polymer system may contain a polymer system based on a urethane resin. Preferably, the layer contains such a urethane resin, which is obtainable by reacting an aliphatic polyisocyanate with hydroxyl-containing polyesters, hydroxyl-containing polyethers or hydroxyl-containing poly (meth) acrylates. In particular, the polyisocyanate component crosslinking to the polyurethane resin may be an aliphatic polyisocyanate based on an HDI monomer. Furthermore, mixed aliphatic / aromatic polyisocyanates are suitable, for example based on TDI and HMDI. Furthermore, already preformed polyurethane resins can be used. Such polyisocyanates or polyurethane resins are commercially available products. Examples include: Desmount ^R 2170, Vesticoat ^R UB 909, Desmodur ^R BL 3475, Desmodur ^R HLBA, Desmodur ^R N 3390, Desmodur ^R N 3790, Desmodur ^R N 75 and Tolonate ^R HDT-LV 2.

The hydroxyl-containing polyesters or hydroxyl-containing poly (meth) acrylates which can be used as the crosslinking component for the polyisocyanate or polyurethane are likewise commercially available under different trade names. Examples include: Desmophen ^R 1100, Desmophen ^R 370, Desmophen ^R A665 BA.

In a further embodiment, the layer b) contains, as crosslinked organic polymer system, a polymer system based on an epoxy resin. This can be selected, for example, by reacting a polyepoxide or epoxy resin prepolymer having residual epoxide groups with one or more curing agents selected from the group: melamine-formaldehyde resins, hydroxyl-containing polyesters, hydroxyl-containing polyethers, hydroxyl-containing poly (meth) acrylates, to be available.

The epoxy component can be selected, for example, from the following commercial raw materials: Beckopox ^R EM 441, Beckopox ^R EP 309, Beckopox ^R EP 401, Araldite ^R GT 6099 and Epikote ^R 109.

The hydroxyl-containing polyesters or hydroxyl-containing poly (meth) acrylates which can be used as hardeners can be selected from the raw materials already mentioned above. For example, the products Desmodur ^R BL 3175 and Desmobur ^R BL 3370 can be used as blocked aliphatic isocyanates based on HDI.

It is particularly preferred in the context of the present invention that the layer b) contains as cross-linked organic polymer system both a polymer system based on a urethane resin and a polymer system based on an epoxy resin. This leads to an optimized property profile in terms of corrosion protection, adhesion of the coating to the substrate, formability and adhesion of a later applied paint on the layer b).

There may be those urethane resins and epoxy resins described above. The invention is then characterized in that the urethane resin is obtainable by reacting a polyisocyanate with hydroxyl-containing polyesters, hydroxyl-containing polyethers or hydroxyl-containing poly (meth) acrylates and that the epoxy resin is selected by reacting a polyepoxide with one or more curing agents from the group: melamine Formaldehyharze, hydroxyl-containing polyester, hydroxyl-containing polyether, hydroxyl-containing poly (meth) acrylates is available.

As a further embodiment, it is particularly preferred that layer b) contains a polymer system which is a reaction product of an epoxy resin present as hydroxyl-containing polyether based on a bisphenol-epichlorohydrin polycondensation product with an aliphatic polyisocyanate. In this embodiment, the epoxy resin present as hydroxyl-containing polyether substantially no more free epoxide groups. Rather, its crosslinking reaction occurs via the hydroxyl groups. It is particularly preferred that in the layer b) the crosslinking is carried out by reaction with an aliphatic polyisocyanate on HDI basis. In this case, it is further preferred that in the layer b), in addition to this polymer system, further polyurethane resins are present which have been formed by reaction of polyisocyanates with hydroxyl-containing polyesters and / or hydroxyl-containing poly (meth) acrylates.

The layer b) may contain aluminum flakes, graphite and / or carbon black as the electrically conductive pigment. The use of graphite and / or carbon black is preferred. Carbon black and especially graphite not only cause electrical conductivity of the layer b), but also contribute to the fact that this layer has the desired low Mohs hardness of not more than 4 and is easy to form. In particular, the lubricating effect of graphite contributes to a reduced wear of the forming tools. This effect can be further promoted by additionally using lubricating pigments, such as, for example, molybdenum sulfide. As further lubricants or forming aids, the layer b) may contain waxes and / or Teflon.

The electrically conductive pigment having a specific weight of at most 3 g / cm ³ may be in the form of small spheres or aggregates of such spheres. It is preferred that the balls or the aggregates of these balls in the layer b) have a diameter of less than 2 microns. However, the electrically conductive pigments are preferably in the form of platelets whose thickness is preferably less than 2 μm.

Furthermore, it is preferred that the layer b) additionally contains corrosion inhibitors and / or anticorrosive pigments. In this case, corrosion inhibitors and / or anticorrosive pigments can be used, which are known in the art for this purpose. Examples include: magnesium oxide pigments, in particular in nanoscale form, finely divided and very finely divided barium sulfate or anticorrosive pigments based on calcium silicate.

The mechanical and chemical properties of layer b) can be further improved by containing silicic acids or silicon oxides. These can also be hydrophobic. Such products are available, for example, under the name Aerosil ^R.

Accordingly, it is preferred that the layer b) in addition to the essential components one or more components selected from

I. corrosion inhibitors and / or anticorrosion pigments, preferably in an amount of from 5 to 60, in particular in an amount of from 10 to 40% by weight,

II. Silicic acids or silicon oxides, preferably in an amount of 0.5 to 5, in particular in an amount of 1 to 3 wt .-%,

III. Lubricants or forming aids, preferably selected from waxes, molybdenum sulfide and Teflon, preferably in an amount of 0.5 to 20, in particular in an amount of 1 to 10 wt .-%, wherein the amounts in wt .-% on the total mass the layer b) relate

In layer b), the proportion of organic binder may be less than the proportion of inorganic pigments. In general, however, it is preferred that the layer b) contains more organic binder than inorganic pigments. The weight ratio of inorganic pigments to organic binders is preferably in the range from 1: 1 to 1: 3, in particular in the range from 1: 1, 5 to 1: 2.

In order to achieve a light and low-wear formability of the metal parts provided with the layer b), in particular metal sheets, it is advantageous if a sheet provided on both sides with the layer system in a tri-bome Reibverschleißversuch without additional BÖLING at a contact pressure in the range of 300 to 700 daN has a coefficient of friction μ below 0.1. Sheets coated in this way can then be formed directly without additional oiling. This makes it possible to save forming oil and simplify the required cleaning before overpainting. This is possible in particular when the layer b) contains graphite as the electrically conductive pigment and both a polymer system based on a urethane resin and a polymer system based on an epoxide as an organic polymer system, as described in greater detail above. Furthermore, it has a favorable effect when the layer b) contains about 0.2 to about 0.5 parts by weight of silica (Aerosil ^R ). A further aspect of the present invention resides in a method for producing a sheet or component which has the above-described layer system comprising a conversion layer a) and the conductive organic layer b). Another object of the present invention is thus a method for producing a sheet or component, wherein the sheet or component to be coated i) cleaned if necessary, ii) brings into contact with a conversion solution which produces the conversion layer a), and then with or without intermediate rinse iii) brings into contact with a liquid treatment agent, which after curing at a substrate temperature in the range of 120 to 260 ⁰ C, the layer b) generates.

Preferably, the curing takes place at a substrate temperature in the range of 150-170 ⁰ C.

Preferably, at least steps (ii) and (iii) are carried out as a strip treatment process, wherein in step (iii) the liquid treatment agent is applied in such an amount that after hardening the desired layer thickness in the range of 0.5 to 2 , 5 μm. Preferably, therefore, the layer b) is applied in the so-called coil coating process. Here, continuous metal strips are continuously coated. The coating composition can be applied by various methods which are familiar in the prior art. For example, applicator rollers can be used with which the desired wet film thickness can be set directly. Alternatively, one may immerse the metal strip in the coating agent or spray it with the coating agent, after which the desired wet film thickness is adjusted by means of squeeze rolls.

If metal strips coated immediately before with a metal coating, for example with zinc or zinc alloys, electrolytically or by hot dip coating, it is not necessary to clean the metal surfaces before carrying out the conversion treatment (ii). However, if the metal strips have already been stored and in particular provided with corrosion protection oils, a purification step is necessary before carrying out step (ii).

After applying the liquid treatment agent in step (iii), the coated sheet is heated to the required drying or crosslinking temperature for the organic coating. The heating of the coated substrate to the required substrate temperature ("peak-metal-temperature" = TMP) in the range from 120 to 260 ^° C., preferably in the range from 150 to 170 ^° C., can be carried out in a heated continuous furnace be brought to the appropriate drying or crosslinking temperature by infrared radiation, in particular by near infrared radiation.

As already explained above in connection with the formed coating, the conversion solution to be used in step (ii) may be a layer-forming or non-layer-forming phosphating solution known in the art. Alternatively, it is possible to use an acidic treatment solution which contains, as a layer-forming component, complex fluorides of silicon and in particular of titanium and / or zirconium. Furthermore, the conversion solution may contain organic polymers such as, for example, polyacrylates or amino-substituted polyvinylphenol derivatives. Addition of nanoscale silicic acid or nanoscale alumina to the conversion solution in step (ii) can lead to further improved corrosion protection and adhesion properties. In this case, "nanoscale" means particles which on average have a particle diameter of less than 1000 nm, in particular of less than 500 nm.

The preferred structure of the organic polymer system in the conductive organic layer b) has been described above. From this it is obvious that the liquid treatment agent used in the treatment step (iii) contains the corresponding reactive polymer components. Reference is made to the comments above.

It is particularly preferred in this case that the liquid treatment agent in step (iii) contains at least one polyisocyanate and at least one reaction component selected from hydroxyl-containing polyesters, hydroxyl-containing polyethers or hydroxyl-containing poly (meth) acrylates. Furthermore, it is particularly preferred that the liquid treatment agent in step (iii) contains at least the following constituents: a polyepoxide with residual epoxide groups and one or more hardeners selected from the group: melamine formaldehyde resins, hydroxyl-containing polyesters, hydroxyl-containing polyethers, Hydroxyl-containing poly (meth) acrylates.

Preferably, this treatment agent contains in each case at least one of the following crosslinkable resin components A) to D):

A) unblocked aliphatic polyisocyanate,

B) blocked aliphatic polyisocyanate,

C) epoxy resin present as hydroxyl group-containing polyether based on a bisphenol-epichlorohydrin polycondensation product,

D) at least one reaction component selected from hydroxyl-containing polyesters and hydroxyl-containing poly (meth) acrylates.

The aliphatic polyisocyanates are preferably based on HDI, in particular on HDI-Thmer. As blocking agents in the blocked aliphatic polyisocyanate B), the customary polyisocyanate blocking agents may be used. Examples which may be mentioned are: butanone oxime, dimethylpyrazole, malonic esters, diisopropylamine / malonic esters, diisopropylamine / thazole and e-caprolactam. Preferably, a combination of malonic ester and diiospropylamine is used as blocking agent.

The abovementioned components are preferably present in the treatment agent in the following proportions, based on the total, solvent-containing coating composition:

A) unblocked aliphatic polyisocyanate: 5 to 20% by weight, preferably 6 to 12% by weight,

B) blocked aliphatic polyisocyanate: 2 to 20% by weight, preferably 3 to 10% by weight,

C) epoxy resin present as hydroxyl group-containing polyether: 2 to 10 wt.%, Preferably 2.4 to 6 wt.

D) hydroxyl-containing polyester and / or hydroxyl-containing poly (meth) acrylate: a total of 10 to 30 wt .-%, preferably 12 to 23 wt .-%.

The organic polymer components which form the organic polymer system of layer b) after curing are usually present in the raw materials as a solution in an organic solvent. Therefore, the coating agent to be used in step (iii) also contains organic solvents. These are desirable in order to set a viscosity despite the additional presence of the electrically conductive pigment such as graphite and optionally other pigments such as in particular anti-corrosion pigments, which allows the coating agent to be applied to the substrate in the coil coating process. If necessary, additional solvent can be added. In general, the coating agent to be applied in step (iii) contains from 25 to 60% by weight, in particular from 35 to 55% by weight, of solvent. The chemical nature of solvents is usually determined by the choice of raw materials, which is the appropriate Solvent included, given. The following may be present as solvents: cyclohexanone, diacetone alcohol, diethylene glycol monobutyl ether acetate, diethylene glycol, propylene glycol methyl ether, propylene glycol n-butyl ether, methoxypropyl acetate, dimethyl succinate, glutaric acid dimethyl ester and / or dimethyl adipate.

Of course, the liquid treatment agent to be applied in step (iii) contains those components in appropriate proportions that are essential or optional as components in the layer b) described above. They are in the liquid treatment agent in the appropriate ratio, but due to the presence of the organic solvent in lower absolute amounts than in the finished layer b). Accordingly, it is preferred in the process according to the invention that the liquid treatment agent in step (iii), based on the total mass of the liquid treatment agent, 1 to 12 wt .-% of an electrically conductive pigment having a specific gravity of not more than 3 g / cm ³ , but not more than 3% by weight of electrically conductive pigment having a specific gravity of more than 3 g / cm ³ .

It is further preferred that in step (iii), based on the total mass of the liquid treatment agent, the liquid treatment agent additionally comprises one or more components selected from

I. corrosion inhibitors and / or anticorrosive pigments, preferably in an amount of from 2.5 to 30, in particular in an amount of from 5 to 20% by weight,

II. Silicic acids or silicon oxides, preferably in an amount of 0.2 to 2.5, in particular in an amount of 0.5 to 1, 5 wt .-%,

III. Lubricants or forming aids, preferably selected from waxes, molybdenum sulfide and Teflon, preferably in an amount of 0.5 to 20, in particular in an amount of 1 to 10 wt .-%. The liquid treatment agent used in step (iii) is preferably designed to contain, based on the total mass of the liquid treatment agent, from 25 to 60% by weight, preferably from 35 to 55% by weight of organic solvent and from 20 to 45% by weight. % Resin components. The remainder to 100% by weight is distributed among the above-mentioned other essential and optional components. However, the sum of resin component and organic solvent may be at most 99 wt .-%, since the agent should contain at least 1 wt .-% conductive pigment. Since the agent is preferably also to contain other solid components such as, in particular, anticorrosive pigments, the sum of resin components and solvent is preferably not greater than 96% by weight and in particular not greater than 85% by weight.

As already described above, a coated sheet according to the invention can be formed without the use of forming oil. In addition to the material savings due to the low layer thicknesses, this saving of forming oil is a significant advantage of the present invention. Accordingly, another aspect of the present invention is a method of manufacturing molded sheet metal components by forming a sheet coated as described above without applying a coating and joining the formed sheet to other sheets by arc welding.

The sheets coated according to the invention are preferably used in vehicle construction and in the household appliance industry. It is customary, after production of the corresponding objects from the coated sheet according to the invention to the layer b) to apply one or more further lacquer layers. In vehicle construction, this is usually done by cathodic electrocoating, which is possible due to the electrical conductivity of the coating. This is followed by the automotive-typical further painting steps. For simpler corrosion protection requirements, such as in the household appliance industry, a powder coating can be applied as topcoat to layer b). Examples

The invention will be explained in more detail by some embodiments.

a) Pretreatment

On a with alkaline cleaners (eg Ridoline ^® C 72, Ridoline ^® 1340; dip, spray cleaning products Anmeldehn) purified, galvanized sheet metal, a commercial pretreatment solution based on phosphoric acid, manganese phosphate, H ₂ TiF ₆ and aminomethyl-substituted polyvinyl phenol (Granodine ^R 1455 Applicant) and spread with a paint spinner or a chemcoater on the metal surface. It is dried at 80 ⁰ C.

b) Preparation instructions and application of the anticorrosive composition:

The organic binders are placed at room temperature in a dissolver and the anticorrosion pigment (mixture) finely dispersed, which may take 10 to 60 minutes. Subsequently, the conductive pigment is added and distributed by slow stirring until complete wetting. This can also take 10 to 60 minutes. Subsequently, if appropriate, solvents and further additives are mixed in.

The anticorrosive composition is applied with a doctor blade or RoII coater on the pretreated sheets and cured by heating in the oven to the substrate temperature specified in the tables.

Test methods:

Corrosion protection test [according to DIN 50021]:

Three edges and the back of the coated test panel are masked with adhesive tape. On one longitudinal side creates a fresh cutting edge. Furthermore, the sheet is provided with a score. Subsequently, the test sheet is in spent the salt spray tester. After certain time intervals, the degree of rust is evaluated at the scribe, edge and on the sheet metal surface. The tables show the number of hours after which red rust is visible on the test panels.

MEK resistance:

A 1 kg weight block is wrapped in cotton wool soaked in methyl ethyl ketone (MEK) and passed over the surface coated with the anticorrosive composition. The number of double strokes needed to remove the coating until the metallic substrate becomes visible is counted and is a measure of solvent resistance.

T-bend test: acc. ECCA test method T7 [1996]: "Resistance to cracking on bending"

The coated sheet is bent by 180 ° with a press brake. An adhesive tape (Tesafilm 4104) is glued to the edge and pulled off abruptly. Cracking at the formed edge is assessed according to DIN 53230.

Reverse impact test: acc. ECCA test method T5 [1985]: "Resistance to cracking during rapid forming"

With a ball impact tester (weight: 2 kg, height: 1 m), the one-sided coated sheets are formed. An adhesive tape (Tesafilm 4104) is glued to the resulting curvature and torn off abruptly. Visually, the amount of coating removed with the adhesive tape is evaluated on a rating scale of 1 to 5. Where: 1: no detached coating; 5: coating largely detached.

Alkali resistance:

According to the reverse impact test, the one-sided coated sheet metal is reshaped. The deformed part is immersed for 10 minutes in a 70 - 80 ⁰ C hot alkaline cleaning solution (Ridoline ^R C72, 1% strength, pH about 13). An adhesive tape (Tesafilm 4104) is glued to the resulting curvature and torn off abruptly. Visually, the amount of coating removed with the adhesive tape becomes evaluated on a rating scale of 1 to 5. Where: 1: no detached coating; 5: coating largely detached.

Welding tests:

With a welding machine of the company Dalex (type PMS 11 -4) electro-welding tests were carried out under typical automotive conditions. Welding points were determined within the DaimlerChrysler specification DBL 4062/4066. This means that the sheets coated with the corrosion inhibitor according to the invention are capable of being electro-welded under practical conditions with sufficient electrode life.

Reibverschleißprüfung:

A test sheet having the coating described on both sides is brought between two pressing jaws which press onto the sheet with a force of Fs. With a force Ft the sheet is pulled upwards. The friction coefficient μ is defined as Ft / (2 Fs).

The press jaws have an area of 1 cm ² each and are pressed with a force between 0 and 2000 daN, wherein the strength of the contact pressure is typically increased by 10 daN per second. The tensile force Ft is varied between 0 and 100 daN with the sample sheet being pulled through the dies at a rate of 1.5 to 200 mm per second.

In the case of coatings according to the invention without additional coating, the coefficient of friction μ after an initial maximum is below 0.1 and is generally in the range between 0.06 and 0.9, measured up to a maximum contact pressure Fs of 800 daN. In a non-inventive coating according to the prior art (Granocoat ^R ) ZE, Henkel KGaA, falls in the same experiment, the coefficient of friction μ does not fall below a value of 0.1. This is still the case even if this comparative coating is coated with 0.5 g / m ^{2 of} forming oil. In practice, these results mean that sheets provided with the coating according to the invention can be formed without additional coating, without being damaged on the one hand and leading to excessive wear of the forming tools on the other hand.

Details of the composition of anticorrosive compositions according to the invention and test results can be found in the following tables. The following abbreviations apply:

PMT: "Peak Metal Temperature": highest substrate temperature reached when curing the coating, MEK: MEK resistance as described above,

prescription data

50,90 48, 57 52, 36 54, 36 48,57 54,36

solid

0.57 0, 33 0, 52 0, 50 0.33 0.50

P / B ratio

32.40 36, 57 34, 53 36, 36 36.57 36.36

Binder content solid

12.00 12, 00 12, 00 12, 00 12.00 12.00

Anticorrosion pigment

18,50 12, 00 18, 00 18, 00 12,00 18,00

pigment content

49.10 51, 43 47, 47 45, 64 51, 43 45.64

solvent

In this case: Component No.

Further examples (component numbers as below)

Where: component no.

Claims

claims

1. Sheet or component made of a metallic material that carries on its surface a layer system comprising at least the following layers: a) a conversion layer that contains no more than 1 mg chromium per m ^2, b) a layer of a crosslinked organic polymer system having a thickness in the range of 0.5 to 2.5 microns, based on the total mass of this layer, 2 to 25 wt .-% of an electrically conductive pigment having a specific gravity of at most 3 g / cm ³ , but not more than 5 wt % electroconductive pigment having a specific gravity greater than 3 g / cm ³ .

2. Sheet or component according to claim 1, characterized in that the metallic material is selected from aluminum or an aluminum alloy, zinc or a zinc alloy, steel or with zinc, aluminum or alloys of zinc or aluminum coated steel.

3. Sheet metal or component according to one or both of claims 1 and 2, characterized in that the conversion layer a) represents a conversion layer formed by layer-forming or non-film-forming phosphating or by treatment with an aqueous solution of complex fluorides of B, Si, Ti , Zr and / or Hf is available.

4. Sheet or component according to one or more of claims 1 to 3, characterized in that the layer b) contains as crosslinked organic polymer system, a polymer system based on a urethane resin.

5. Sheet or component according to claim 4, characterized in that the urethane resin is obtainable by reacting an aliphatic polyisocyanate with hydroxyl-containing polyesters, hydroxyl-containing polyethers or hydroxyl-containing poly (meth) acrylates.

6. Sheet or component according to one or more of claims 1 to 3, characterized in that the layer b) contains as a crosslinked organic polymer system, a polymer system based on an epoxy resin

7. Sheet or component according to claim 6, characterized in that the epoxy resin by reaction of a polyepoxide with residual epoxide groups with a hardener or a plurality of hardeners selected from the group: MeI- amine Formaldehyharze, hydroxyl-containing polyesters, hydroxyl-containing polyethers, Hydroxyl-containing poly (meth) acrylates is available.

8. Sheet or component according to one or more of claims 1 to 7, characterized in that the layer b) contains as crosslinked organic polymer system, both a polymer system based on a urethane resin and a polymer system based on an epoxy resin.

9. sheet or component according to claim 8, characterized in that the urethane resin is obtainable by reacting a polyisocyanate with hydroxyl-containing polyesters, hydroxyl-containing polyethers or hydroxyl-containing poly (meth) acrylates and that the epoxy resin by reacting a polyepoxide with a Hardener or more hardeners selected from the group: melamine Formaldehyharze, hydroxyl-containing polyesters, hydroxyl-containing polyether, hydroxyl-containing poly (meth) acrylates is available.

10. Sheet or component according to one or more of claims 1 to 7, characterized in that the layer b) contains a polymer system comprising a reaction product of an existing as hydroxyl-containing polyether epoxy resin based on a bisphenol-epichlorohydrin polycondensation product with an aliphatic polyisocyanate represents.

11. Sheet or component according to claim 10, characterized in that the layer b) additionally contains a urethane resin, which is obtainable by reacting a polyisocyanate with hydroxyl-containing polyesters or hydroxyl-containing poly (meth) acrylates.

12. Sheet or component according to one or more of claims 1 to 11, characterized in that the layer contains b) as an electrically conductive pigment graphite and / or carbon black.

13. Sheet or component according to one or more of claims 1 to 12, characterized in that the layer b) additionally one or more components selected from

III. Lubricants or forming aids, preferably selected from waxes, molybdenum sulfide and Teflon, preferably in an amount of 0.5 to 20, in particular in an amount of 1 to 10 wt .-%, wherein the amounts in wt .-% on the total mass the layer b) relate.

14. sheet or component according to one or more of claims 1 to 13, characterized in that it provided in both sides with the layer system state in a tribometer Reibverschleißversuch without additional BeÖlung at a contact pressure in the range of 300 to 700 daN a coefficient of friction μ below 0.1.

15. Sheet or component according to one or more of claims 1 to 14, characterized in that the layer b) a Mohs hardness of not has more than 4.

16. A method for producing a sheet or component according to one or more of claims 1 to 15, characterized in that one cleans the sheet or component to be coated i) if necessary, ii) brings into contact with a conversion solution which produces the conversion layer a) and then with or without intermediate rinse, iii) contacting a liquid treating agent which, after curing, produces the layer b) at a substrate temperature in the range of 120 to 260 ^° C.

17. Process according to claim 16, wherein a coated strip-shaped sheet is produced by carrying out at least steps ii) and iii) as a strip treatment method and in step iii) applying the liquid treatment agent in such an amount that after curing obtains a layer thickness in the range of 0.5 to 2.5 microns.

18. The method according to one or both of claims 16 and 17, characterized in that the liquid treatment agent in step iii) at least one polyisocyanate and at least one reaction component selected from hydroxyl-containing polyesters, hydroxyl-containing polyethers and hydroxyl-containing poly (meth) contains acrylates.

19. The method according to one or both of claims 16 and 17, characterized in that the liquid treatment agent in step iii) at least one polyepoxide with residual epoxide groups and one or more hardeners selected from the group: melamine-formaldehyde resins, hydroxyl-containing polyesters, Hydroxyl-containing polyether containing hydroxyl-containing poly (meth) acrylates.

20. The method according to one or both of claims 16 and 17, characterized in that the liquid treatment agent in step iii) each contains at least one of the following crosslinkable resin components A) to D):

A) unblocked aliphatic polyisocyanate,

B) blocked aliphatic polyisocyanate,

D) at least one reaction component selected from hydroxyl-containing polyesters and hydroxyl-containing poly (meth) - acrylates.

21. The method according to one or more of claims 16 to 20, characterized in that the liquid treatment agent in step iii), based on the total mass of the liquid treatment agent, 1 to 12 wt .-%, preferably 4 to 8 wt .-% of a electrically conductive pigment having a specific gravity of at most 3 g / cm ³ , but not more than 3 wt .-% electrically conductive pigment having a specific gravity of more than 3 g / cm ³ .

22. The method according to one or more of claims 16 to 21, characterized in that the liquid treatment agent in step iii), based on the total mass of the liquid treatment agent, additionally one or more components selected from

III. Lubricants or forming aids, preferably selected from waxes, molybdenum sulfide and Teflon, preferably in an amount of 0.5 to 20, in particular in an amount of 1 to 10 wt .-%.

23. The method according to one or more of claims 16 to 22, characterized in that the liquid treatment agent in step iii), based on the total mass of the liquid treatment agent, 25 to 60 wt .-%, preferably 35 to 55 wt .-% organic Solvent and 20 to 45 wt .-% resin components.

24. A method for producing shaped components from sheet metal, wherein one transforms a sheet according to one or more of claims 1 to 15 without applying a BEÖlung and merges the formed sheet by arc welding with other sheets.