JP6080670B2 - 塗装鋼板用下地処理組成物、並びに下地処理されためっき鋼板およびその製造方法、塗装めっき鋼板およびその製造方法 - Google Patents
塗装鋼板用下地処理組成物、並びに下地処理されためっき鋼板およびその製造方法、塗装めっき鋼板およびその製造方法 Download PDFInfo
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- JP6080670B2 JP6080670B2 JP2013089484A JP2013089484A JP6080670B2 JP 6080670 B2 JP6080670 B2 JP 6080670B2 JP 2013089484 A JP2013089484 A JP 2013089484A JP 2013089484 A JP2013089484 A JP 2013089484A JP 6080670 B2 JP6080670 B2 JP 6080670B2
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- 230000009467 reduction Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000007142 ring opening reaction Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
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- 125000000467 secondary amino group Chemical group [H]N([*:1])[*:2] 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- NVKTUNLPFJHLCG-UHFFFAOYSA-N strontium chromate Chemical compound [Sr+2].[O-][Cr]([O-])(=O)=O NVKTUNLPFJHLCG-UHFFFAOYSA-N 0.000 description 1
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- 239000002344 surface layer Substances 0.000 description 1
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- 239000002335 surface treatment layer Substances 0.000 description 1
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- 230000002194 synthesizing effect Effects 0.000 description 1
- 239000008399 tap water Substances 0.000 description 1
- 235000020679 tap water Nutrition 0.000 description 1
- 150000000000 tetracarboxylic acids Chemical class 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 1
- RUELTTOHQODFPA-UHFFFAOYSA-N toluene 2,6-diisocyanate Chemical compound CC1=C(N=C=O)C=CC=C1N=C=O RUELTTOHQODFPA-UHFFFAOYSA-N 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- 150000003628 tricarboxylic acids Chemical class 0.000 description 1
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 1
- QXJQHYBHAIHNGG-UHFFFAOYSA-N trimethylolethane Chemical compound OCC(C)(CO)CO QXJQHYBHAIHNGG-UHFFFAOYSA-N 0.000 description 1
- UNXRWKVEANCORM-UHFFFAOYSA-N triphosphoric acid Chemical compound OP(O)(=O)OP(O)(=O)OP(O)(O)=O UNXRWKVEANCORM-UHFFFAOYSA-N 0.000 description 1
- GRUMUEUJTSXQOI-UHFFFAOYSA-N vanadium dioxide Chemical compound O=[V]=O GRUMUEUJTSXQOI-UHFFFAOYSA-N 0.000 description 1
- 229910001935 vanadium oxide Inorganic materials 0.000 description 1
- JBIQAPKSNFTACH-UHFFFAOYSA-K vanadium oxytrichloride Chemical compound Cl[V](Cl)(Cl)=O JBIQAPKSNFTACH-UHFFFAOYSA-K 0.000 description 1
- HQYCOEXWFMFWLR-UHFFFAOYSA-K vanadium(iii) chloride Chemical compound [Cl-].[Cl-].[Cl-].[V+3] HQYCOEXWFMFWLR-UHFFFAOYSA-K 0.000 description 1
- UUUGYDOQQLOJQA-UHFFFAOYSA-L vanadyl sulfate Chemical compound [V+2]=O.[O-]S([O-])(=O)=O UUUGYDOQQLOJQA-UHFFFAOYSA-L 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- UKRDPEFKFJNXQM-UHFFFAOYSA-N vinylsilane Chemical compound [SiH3]C=C UKRDPEFKFJNXQM-UHFFFAOYSA-N 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
- PAPBSGBWRJIAAV-UHFFFAOYSA-N ε-Caprolactone Chemical compound O=C1CCCCCO1 PAPBSGBWRJIAAV-UHFFFAOYSA-N 0.000 description 1
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- B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
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- B—PERFORMING OPERATIONS; TRANSPORTING
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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
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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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- 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
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- Application Of Or Painting With Fluid Materials (AREA)
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Description
(1) 有機ケイ素化合物(A)と、
ヘキサフルオロ金属酸(B)と、
カチオン性基を有するウレタン樹脂(C)と、
バナジウム化合物(D)と、
水性媒体(E)
を含む塗装鋼板用下地処理組成物であって、
該有機ケイ素化合物(A)が、第一級アミノ基を有するアミノシラン化合物の、加水分解物、加水分解縮合物、及びそれらの混合物から選ばれ、
該ウレタン樹脂(C)のカチオン性基が、下記一般式〔I〕で示されるカチオン性基であり、
該カチオン性基が、該ウレタン樹脂(C)中に0.03〜0.15mol/kgの範囲で含まれ、
該ウレタン樹脂(C)の全アミン価が1〜10mgKOH/gである
塗装鋼板用下地処理組成物。
(2) 前記ケイ素化合物(A)の第一級アミノ基(NH2)のモル数に対する前記ヘキサフルオロ金属酸(MF6)(B)のモル数の比〔MF6/NH2〕が0.2〜0.4であり、
前記カチオン性ウレタン樹脂(C)に対する、前記有機ケイ素化合物(A)及び前記ヘキサフルオロ金属酸(B)の合計の固形分質量比〔(A+B)/C〕が1.0〜5.0であり、
バナジウム化合物(D)の含有量が、当該塗装鋼板用下地処理組成物の全固形分に対して0.01〜5.0質量%
である(1)に記載の塗装鋼板用下地処理組成物。
(3) 前記カチオン性基を有するウレタン樹脂(C)が、ポリカーボネート構造単位及びポリエーテル構造単位を有する(1)又は(2)に記載の塗装鋼板用下地処理組成物。
(4) 前記ヘキサフルオロ金属酸(B)が、ヘキサフルオロジルコニウム酸、ヘキサフルオロチタン酸、またはそれらの混合物から選ばれる(1)〜(3)のいずれかに記載の塗装鋼板用下地処理組成物。
(5) めっき鋼板の少なくとも一方の表面上に、(1)〜(4)のいずれかに記載の塗装鋼板用下地処理組成物用いて形成された下地処理層を0.01〜0.5g/m2の量で有する下地処理されためっき鋼板。
(6) 該めっき鋼板が、溶融Zn−55%Al−1.6%Si合金めっき鋼板、めっき層が質量%でAl:25〜75%、Mg:0.1〜10%、Si:1〜7.5%、Cr:0.05〜5.0%、Ca及びSrの少なくとも1種類以上:0.001〜0.5%を含有し、残部がZn及び不可避的な不純物であるZn−Al−Mg−Si−Cr−Ca(Sr)合金めっき鋼板、めっき層が質量%でAl:2〜19%、Mg:1〜10%、Si:0.01〜2%を含有し、残部がZn及び不可避的不純物であるZn−Al−Mg−Si合金めっき鋼板から選ばれる(5)に記載の下地処理されためっき鋼板。
(7) めっき鋼板の少なくとも一方の表面上に、順に、
(1)〜(4)のいずれかに記載の塗装鋼板用下地処理組成物を含む下地処理層と、
プライマー層と、
着色顔料を含有するトップ層と
を有する、塗装めっき鋼板であって、
該プライマー層が、該有機ケイ素化合物(A)の第一級アミノ基と反応することができる官能基を有する樹脂及び防錆顔料含有する、塗装めっき鋼板。
(8) 該めっき鋼板が、溶融Zn−55%Al−1.6%Si合金めっき鋼板、めっき層が質量%でAl:25〜75%、Mg:0.1〜10%、Si:1〜7.5%、Cr:0.05〜5.0%、Ca及びSrの少なくとも1種類以上:0.001〜0.5%を含有し、残部がZn及び不可避的な不純物からなるZn−Al−Mg−Si−Cr−Ca(Sr)合金めっき鋼板、めっき層が質量%でAl:2〜19%、Mg:1〜10%、Si:0.01〜2%を含有し、残部がZn及び不可避的不純物からなるZn−Al−Mg−Si合金めっき鋼板から選ばれる(7)に記載の塗装めっき鋼板。
(9) (1)〜(4)のいずれかに記載の塗装鋼板用下地処理組成物を、めっき鋼板の少なくとも一方の表面上に塗布し、
水洗することなく加熱乾燥して当該表面に下地処理層を形成させる下地処理工程を含む下地処理されためっき鋼板の製造方法。
(10) (9)に記載の下地処理工程の後に、さらにプライマー組成物を塗布し、加熱乾燥してプライマー層を形成する塗装工程と、該プライマー層の上にトップ塗料を塗布した後、加熱乾燥してトップ層を形成させる工程とを含む塗装めっき鋼板の製造方法。
1. 下地処理組成物(実施例用No.1〜35)
表1に示す原料の組み合わせ、配合比にて水系下地処理組成物を調製した。脱イオン水にアミノシラン化合物を添加し5分間攪拌した後、ヘキサフルオロ金属酸を添加し10分間攪拌して中和物を得た。次いで、ウレタン樹脂、バナジウム化合物を順次添加し、十分に混合させるため10分間攪拌し、水系下地処理組成物を得た。脱イオン水を加えて固形分濃度を7質量%に調整した。
(1)ポリエーテル系ウレタン樹脂エマルション(C1)
1,4−シクロヘキシルグリコールから得られるポリエーテルポリオール(以下、ポリエーテルAという)120質量部、1,4−シクロヘキサンビスメチルイソシアネート100質量部、N−メチルジエタノールアミン10質量部、トリメチロールプロパン5質量部をN−メチル−2−ピロリドン100質量部中で70℃に保ちながら反応させることにより得られるウレタンプレポリマーに、硫酸ジメチル3質量部を添加し、50℃で60分間反応させてカチオン性ウレタンプレポリマーを得た。次いで、脱イオン水を加えて均一に乳化分散させた後、N−メチル−2−ピロリドンを回収してカチオン性ポリウレタン樹脂エマルションを得た。
ポリオールとして、1,4−シクロヘキサンジメタノールとジフェニルカーボネートから得られるポリカーボネートジオールから得られるポリカーボネートポリオール(以下、ポリカーボネートAという)120質量部を用いた以外は、C1と同様に合成した。
ポリオールとして、1,4−シクロヘキシルグリコールとアジピン酸から得られるポリエステルポリオール(以下、ポリエステルAという)120質量部を用いた以外は、C1と同様に合成した。
ポリオールとして、ポリエーテルA84質量部、ポリカーボネートA36質量部を用いた以外は、C1と同様に合成した。
ポリオールとして、テトラメチレングリコールから得られるポリエーテルポリオール(以下、ポリエーテルBという)84質量部、ポリカーボネートA36質量部を用いた以外は、C1と同様に合成した。
ポリオールとして、ポリエーテルA84質量部、1、6−ヘキサンジオールとジフェニルカーボネートから得られるポリカーボネートジオールから得られるポリカーボネートポリオール(以下、ポリカーボネートBという)36質量部を用いた以外は、C1と同様に合成した。
ポリオール、イソシアネート、導入アミン、カチオン化成分の各々を表2に示す組み合わせ、配合量とした以外は、C1と同様に合成した。C13およびC16は乳化不良により、エマルションには成らず水分散性は悪い。
(カチオン性ウレタン樹脂(C)のカチオン性基量)
ウレタン樹脂エマルションを合成する際の原料成分の仕込み量から下記計算式により算出する値をカチオン性基量として定義する。得られたウレタン樹脂エマルションのカチオン性基量を表3に示す。
式中:
G1:ポリオールの投入量(g)
G2:イソシアネートの投入量(g)
G3:2個以上のヒドロキシル基もしくはアミノ基と1個以上の三級アミンおよび/又は四級アンモニウム基を有する化合物の投入量(g)
G4:中和酸及び/またはカチオン化剤の投入量(g)
H4:中和酸及び/またはカチオン化剤の分子量(g/mol)
である。
下記の測定方法により測定した値を全アミン価として定義する。得られたウレタン樹脂エマルションの全アミン価を表3に示す。
全アミン価=[(F1−F2)×f×5.611/S]
式中:
F1:本試験に要した0.1mol/L塩酸滴定用溶液量(mL)
F2:空試験に要した0.1mol/L塩酸滴定用溶液量(mL)
f:0.1mol/L塩酸滴定用溶液の力価
S:試料採取量(g)
である。
前記特許文献1〜4の実施例に記載の下記の水系下地処理組成物を調製した。
(1)水系下地処理組成物(No.36)
純水1リットルにサイラエースS−330(γ−アミノプロピルトリエトキシシラン;チッソ社製)を1.5g添加して室温で5分間撹拌し、次いでスノーテックスN(水分散性シリカ;日産化学工業社製)を0.5g添加し5分間撹拌、更にジルコゾールAC−7(炭酸ジルコニルアンモニウム;第一稀元素社製)をジルコニウムイオン換算で0.02g添加し5分間撹拌して水系下地処理組成物(No.36)を得た。
〈ポリウレタン樹脂の合成〉
ポリエーテルポリオール( 合成成分: ポリテトラメチレングリコール及びエチレングリコール、分子量1 5 0 0 ) 1 5 0 質量部、トリメチロールプロパン6 質量部、N − メチル− N , N − ジエタノールアミン2 4 質量部、イソホロンジイソシアネート9 4 質量部及びメチルエチルケトン1 3 5 質量部を反応容器に入れ、7 0 〜 7 5 ℃ に保ちながら反応させて得たウレタンプレポリマーに、ジメチル硫酸1 5 質量部を添加し、5 0 〜 6 0 ℃ で3 0〜 6 0 分間反応させてカチオン性ウレタンプレポリマーを得た。さらに水5 7 6 質量部を前記カチオン性ウレタンプレポリマーに添加し、均一に乳化させた後、メチルエチルケトンを回収してカチオン性ポリエーテル系ウレタン樹脂の水分散体 を得た。該ウレタン樹脂のカチオン性基の量は0.42、全アミン価は30であった。
〈ポリウレタン樹脂の合成〉
「ジェファーミンM−2070」(商品名、ハンツマン社製)200質量部、グリセリンカーボネート11.8質量部を加え、100℃で1時間攪拌し、ポリエーテルアミン変性グリセリンカーボネートを得た。次いで、「ビスオール3PN」(商品名、東邦化学社製)59.5質量部、「ビスオール6PN」(商品名、東邦化学社製)85.7質量部、メチルジエタノールアミン21.1質量部、上記ポリエーテルアミン変性グリセリンカーボネート53.0質量部をN−メチルピロリドン66.2gに溶解し、ヘキサメチレンジイソシアネート67.3質量部を30分かけて滴下し、60℃で1.5時間反応を行った。その後80℃に昇温し2時間反応を行って、イソホロンジイソシアネート44.4g質量部を加え更に80℃で3時間反応させた。その後、メチルエチルケトン154.4質量部を加え、40℃に冷却してプレポリマーを得た。次いで、上記プレポリマーを89%リン酸水溶液6.5質量部で中和し、脱イオン水772.0質量部を加えて分散し、その後70℃に昇温して、1時間保持した。その後、60℃でメチルエチルケトンを減圧留去することで、ポリウレタン樹脂の水性分散体を得た。該ウレタン樹脂のカチオン性基の量は0.18、全アミン価は15であった。
脱イオン水中に、ヘキサフルオロチタン酸55質量部、ヘキサフルオロジルコニウム酸10質量部、アミノメチル置換ポリビニルフェノール72質量部を順次混合し、水系下地処理組成物(No.39)を得た。
塗布クロメート薬剤であるZM−1300AN(日本パ−カライジング(株)製)を用いた。この例は、従来技術のクロメート下地処理組成物の例である。
(1)プライマー組成物(P1)
エポキシ樹脂70質量部、メラミン樹脂10質量部、リン酸亜鉛系防錆顔料5質量部、リン酸マグネシウム系防錆顔料5質量部、トリポリリン酸2水素アルミニウム5質量部及び変性シリカ5質量部を混合し、プライマー組成物P1を得た。
ポリエステル樹脂70質量部、メラミン樹脂10質量部、リン酸亜鉛系防錆顔料5質量部、リン酸マグネシウム系防錆顔料5質量部、トリポリリン酸2水素アルミニウム5質量部及び変性シリカ5質量部を混合し、プライマー組成物P2を得た。
ウレタン樹脂80質量部、リン酸亜鉛系防錆顔料5質量部、リン酸マグネシウム系防錆顔料5質量部、トリポリリン酸2水素アルミニウム5質量部及び変性シリカ5質量部を混合し、プライマー組成物P3を得た。
エポキシ樹脂70質量部、メラミン樹脂10質量部、酸化チタン20質量部を混合し、プライマー組成物P4を得た。
前記特許文献3を参考に、エポキシ樹脂55質量部、リン酸水素マグネシウム系防錆顔料15質量部、リン酸亜鉛系防錆顔料15質量部、トリポリリン酸2水素アルミニウム2質量部、シリカ粉末3質量部、酸化チタン5質量部、硫酸バリウム5質量部を混合し、プライマー組成物P5を得た。
エポキシ樹脂55質量部、メラミン樹脂5質量部、クロム酸ストロンチウム系防錆顔料20リン酸亜鉛系防錆顔料5質量部、リン酸マグネシウム系防錆顔料5質量部、トリポリリン酸2水素アルミニウム5質量部及び変性シリカ5質量部を混合し、プライマー組成物Crを得た。
ポリエステル樹脂60質量部、ブチル化メラミン樹脂15質量部、酸化チタン10質量部及び着色顔料15質量部で混合し、トップ塗料(T1)を得た。
1. めっき鋼板として、以下に示すめっき鋼板を用いた。
・溶融Zn−55%Al−1.6%Si合金めっき鋼板(以下記号:G1)
板厚0.6mm、めっき付着量片面当たり75g/m2(両面めっき)
・溶融Zn−55%Al−2%Mg−1.6%Si−0.1%Cr−0.02%Ca合金めっき鋼板(以下記号:G2)
板厚0.6mm、めっき付着量片面当たり50g/m2(両面めっき)
・溶融Zn−11%Al−3%Mg−0.2%Si合金めっき鋼板(以下記号:G3)
板厚0.6mm、めっき付着量片面当たり50g/m2(両面めっき)
・溶融亜鉛めっき鋼板(以下記号:G4)
板厚0.6mm、めっき付着量片面当たり50g/m2(両面めっき)
アルカリ脱脂剤であるFC−E6406(日本パ−カライジング(株)製)を濃度20g/L、温度60℃で建浴し、上記供試材を10秒間スプレー処理した。次いで、水道水で洗浄した後に、水切りロールで絞り、熱風乾燥した。
(1) 下地処理
表4に示す組み合わせの通り、前処理後のめっき鋼板の表面に水系下地処理組成物を表4に示す乾燥皮膜量(Cr:はCr付着量g/m2を表す)となるようにバーコーターを用いて塗布した。次いで、熱風乾燥炉にて到達板温度が80℃となるよう加熱乾燥した。
表4に示す組み合わせの通り、下地処理されためっき鋼板にプライマー組成物を5μmの乾燥膜厚となるようにバーコーターを用いて塗布した。次いで、熱風乾燥炉にて210℃の到達板温度となるように加熱乾燥した。
表4に示す組み合わせの通り、プライマー層を形成させた後にトップ塗料を15μmの乾燥膜厚となるようにバーコーターを用いて塗布した。次いで、熱風乾燥炉にて220℃の到達板温度となるように加熱乾燥した。
1. 加工密着性
(1) 一次密着性試験
各試験板に対し内側間隔板を挟まない0T折曲げ試験を20℃で行い、テープ剥離後の塗膜剥離状態を肉眼で観察し、下記の判定基準に準じて評価を行った。
◎:剥離なし
○:剥離面積10%未満
△:剥離面積10%以上50%未満
×:剥離面積50%以上
各試験板を沸水中に2時間浸漬した後、1日放置し、一次密着性試験と同様に評価を行った。
(1)複合サイクル試験
各試験板の塗膜に、金属素地に達する疵をカッターで入れ、JASO M609−91に規定された複合サイクル試験を200サイクル実施した。カット部からの塗膜膨れ幅(片側最大値)、および切断端面部からの塗膜膨れ幅(最大値)を測定し、下記の判定基準に準じて評価を行った。
◎:2mm未満
○:2mm以上5mm未満
△:5mm以上10mm未満
×:10mm以上
◎:2mm未満
○:2mm以上5mm未満
△:5mm以上10mm未満
×:10mm以上
各試験板の塗膜に、金属素地に達する疵をカッターで入れ、沖縄県南城市の太平洋岸から約5m内陸にある曝露試験場で屋外曝露試験を約3年間実施した。カット部からの塗膜膨れ幅(片側最大値)、および切断端面部からの塗膜膨れ幅(最大値)を測定し、下記の判定基準に準じて評価を行った。
◎:1mm未満
○:1mm以上2mm未満
△:2mm以上3mm未満
×:3mm以上
◎:1mm未満
○:1mm以上2mm未満
△:2mm以上3mm未満
×:3mm以上
各試験板の塗膜に、金属素地に達する疵をカッターで入れ、沖縄県南城市の太平洋岸から約5m内陸にある曝露試験場で、図1に示す曝露架台の裏側に地面に向けて試験板を設置し、軒下曝露試験を約3年間実施し、上記屋外曝露試験と同様の評価を行った。
(1) 耐アルカリ試験
各試験板を5質量%の水酸化ナトリウム水溶液に室温で24時間浸漬した後、発生したブリスターの大きさと発生密度を肉眼で観察し、下記の判定基準に従って耐アルカリ性の評価を行った。
◎:ブリスターなし。
○:1つのブリスターが1.0mm未満で、かつ発生密度がFである。
△:1つのブリスターが1.0mm以上で、かつ発生密度がFである。もしくは、1つのブリスターの大きさが1.0mm未満で、かつ発生密度がMである。
×:1つのブリスターの大きさが1mm以上で、かつ発生密度がMである。もしくは、ブリスターの大きさに関わらず発生密度がDである。
F:ブリスター発生個数が少ない。
M:ブリスター発生個数が多い。
D:ブリスター発生個数が非常に多い。
各試験板を5質量%の硫酸水溶液に室温で24時間浸漬した後、発生したブリスターの大きさと発生密度を肉眼で観察し、耐アルカリ試験と同様の判定基準で評価を行った。
屋外曝露、軒下曝露でのカソードに起因する腐食を模擬する方法の一つとして、電気化学的にカソードを作り出し、アルカリ濃縮環境下での下地処理皮膜の密着性を評価する試験を実施した。各試験片の塗膜に長さ8mmの金属素地に達する疵をカッターで入れ、5質量%NaCl水溶液中で試験片の疵部に対して1×10-4Aの条件で定電流印加し、72時間保持した。その後、テープ剥離法により疵部からの塗膜膨れ幅(片側最大値)を測定し、下記の判定基準に準じて評価を行った。
◎:1.0mm未満
○:1.0mm以上2mm未満
△:2mm以上3mm未満
×:3mm以上
水系下地処理組成物を40℃の恒温装置中に3ヶ月貯蔵した後、ゲル化又は沈殿の状態を肉眼で観察し、次の基準に従って貯蔵安定性を評価した。
○:変化無し
△:増粘または僅かに沈殿が発生
×:ゲル化または沈殿が発生
表4に試験結果を示す。表4より、本発明の水系下地処理組成物を用いて形成された下地処理層を有する塗装めっき鋼板である実施例1〜32は、一次加工密着性、二次加工密着性、複合サイクル試験での耐食性、屋外曝露耐食性、耐軒下耐食性、耐酸性、耐アルカリ性、及び耐アルカリ密着性の全ての性能において優れた結果を示し、クロメート系である比較例17、22、27と同などの性能を示すことがわかる。一方、ウレタン樹脂(C)の全アミン価が規定の範囲を超える比較例1、カチオン性基の量が規定の範囲を超える比較例2は、耐軒下耐食性、耐アルカリ密着性が不十分であることがわかる。
Claims (7)
- 有機ケイ素化合物(A)と、
ヘキサフルオロ金属酸(B)と、
カチオン性基を有するウレタン樹脂(C)と、
バナジウム化合物(D)と、
水性媒体(E)
を含む塗装鋼板用下地処理組成物であって、
前記有機ケイ素化合物(A)が、第一級アミノ基を有するアミノシラン化合物の、加水分解物、加水分解縮合物、及びそれらの混合物から選ばれ、
前記ウレタン樹脂(C)のカチオン性基が、下記一般式〔I〕で示されるカチオン性基であり、
前記カチオン性基が、前記ウレタン樹脂(C)中に0.03〜0.15mol/kgの範囲で含まれ、
前記ウレタン樹脂(C)の全アミン価が1〜10mgKOH/gである
塗装鋼板用下地処理組成物。 - 前記ケイ素化合物(A)の第一級アミノ基(NH2)のモル数に対する前記ヘキサフルオロ金属酸(MF6)(B)のモル数の比〔MF6/NH2〕が0.2〜0.4であり、
前記カチオン性ウレタン樹脂(C)に対する、前記有機ケイ素化合物(A)及び前記ヘキサフルオロ金属酸(B)の合計の固形分質量比〔(A+B)/C〕が1.0〜5.0であり、
バナジウム化合物(D)の含有量が、前記塗装鋼板用下地処理組成物の全固形分に対して0.01〜5.0質量%
である請求項1に記載の塗装鋼板用下地処理組成物。 - 前記カチオン性基を有するウレタン樹脂(C)が、ポリカーボネート構造単位及びポリエーテル構造単位を有する請求項1又は2に記載の塗装鋼板用下地処理組成物。
- 前記ヘキサフルオロ金属酸(B)が、ヘキサフルオロジルコニウム酸、ヘキサフルオロチタン酸、またはそれらの混合物から選ばれる請求項1〜3のいずれか1項に記載の塗装鋼板用下地処理組成物。
- めっき鋼板の少なくとも一方の表面上に、順に、
請求項1〜4のいずれか1項に記載の塗装鋼板用下地処理組成物を含む下地処理層と、
プライマー層と、
着色顔料を含有するトップ層と
を有する、塗装めっき鋼板であって、
前記プライマー層が、前記有機ケイ素化合物(A)の第一級アミノ基と反応することができる官能基を有する樹脂及び防錆顔料含有する、塗装めっき鋼板。 - 前記防錆顔料が、リン酸系防錆顔料、モリブデン酸系防衛顔料、バナジウム系防錆顔料、微粒シリカから成る群より選ばれる請求項5に記載の塗装めっき鋼板。
- 前記めっき鋼板が、溶融Zn−55%Al−1.6%Si合金めっき鋼板、めっき層が質量%でAl:25〜75%、Mg:0.1〜10%、Si:1〜7.5%、Cr:0.05〜5.0%、Ca及びSrの少なくとも1種類以上:0.001〜0.5%を含有し、残部がZn及び不可避的な不純物からなるZn−Al−Mg−Si−Cr−Ca(Sr)合金めっき鋼板、めっき層が質量%でAl:2〜19%、Mg:1〜10%、Si:0.01〜2%を含有し、残部がZn及び不可避的不純物からなるZn−Al−Mg−Si合金めっき鋼板から選ばれる請求項5または6に記載の塗装めっき鋼板。
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