JPH03219086A - 潤滑性に優れた金属表面処理組成物 - Google Patents

潤滑性に優れた金属表面処理組成物

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Publication number
JPH03219086A
JPH03219086A JP2011747A JP1174790A JPH03219086A JP H03219086 A JPH03219086 A JP H03219086A JP 2011747 A JP2011747 A JP 2011747A JP 1174790 A JP1174790 A JP 1174790A JP H03219086 A JPH03219086 A JP H03219086A
Authority
JP
Japan
Prior art keywords
composition
surface treatment
film
metal surface
lubricant
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP2011747A
Other languages
English (en)
Inventor
Masayasu Ara
真康 荒
Akira Kato
晃 加藤
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nihon Parkerizing Co Ltd
Original Assignee
Nihon Parkerizing Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nihon Parkerizing Co Ltd filed Critical Nihon Parkerizing Co Ltd
Priority to JP2011747A priority Critical patent/JPH03219086A/ja
Priority to CN91100513A priority patent/CN1043242C/zh
Priority to KR1019910001103A priority patent/KR930007152B1/ko
Publication of JPH03219086A publication Critical patent/JPH03219086A/ja
Priority to US08/061,341 priority patent/US5378291A/en
Pending legal-status Critical Current

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    • C09D125/00Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Coating compositions based on derivatives of such polymers
    • C09D125/02Homopolymers or copolymers of hydrocarbons
    • C09D125/04Homopolymers or copolymers of styrene
    • C09D125/08Copolymers of styrene
    • C09D125/14Copolymers of styrene with unsaturated esters
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    • C09D133/00Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/04Homopolymers or copolymers of esters
    • C09D133/06Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
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Abstract

(57)【要約】本公報は電子出願前の出願データであるた
め要約のデータは記録されません。

Description

【発明の詳細な説明】 〔産業上の利用分野〕 本発明は金属表面を同時にクロメート処理及び有機樹脂
コーティング処理し、かつ潤滑処理する組成物に関する
本発明の金属表面処理組成物の一般的用途は、鉄鋼、ア
ルミニウム、亜鉛、錫、銅及びそれら金属の合金、さら
にこれらの金属のめっき材などの素材力(コイル状、板
状、線状、あるいは棒状などの時点でその表面に処理し
、これら素材に潤滑性、成形加工性、耐食性、塗膜密着
性、塗装後耐食性及び耐指紋付着性などを付与した表面
処理済み金属素材を製造するための金属表面処理である
〔従来の技術〕
従来、金属加工及び金属塗装分野において、耐食性の向
上や塗料との密着性向上を目的として上記金属素材に機
械加工後又は塗装前にクロメート処理、リン酸塩処理な
どの表面処理が一般的に実施されている。近年、工程の
省略、コストの低減を目的として上記金属素材を予め表
面処理して皮膜を形成し、その後、プレス油塗布後機械
加工又は脱脂後塗装を行い製品を得ることにより、製品
の段階でのクロメート処理、リン酸塩処理といった表面
処理を省略する試みがなされ、一部現実化している。素
材段階で予め実施する表面処理としては、特にクロメー
ト含有水系樹脂をコーティングする方式が注目され、反
応型クロメート処理を施した後水洗し、有機樹脂を主成
分とする薬剤をコーティングする方法、及びクロメート
薬剤を配合した水系樹脂(以下クロメート含有水系樹脂
とする。)をコーティングする方法が代表的クロメート
含有樹脂系コーティング法として提案されている。前者
の方法は特開昭58−224175号などに、又後者の
方法は特開昭63−145785号などに開示されてい
る。これらの方法は、製品のクロメート処理が省略でき
ることよる工程の省力化及びコスト低減の面で優れてい
た方法である。また、後者の特開昭63−145785
号の方法は本出願人の共同出願にかかる方法であり、こ
の方法により製造された表面処理材は耐食性、塗膜密着
性、塗装後耐食性、耐指紋付着性に優れ、又アルカリ脱
脂後、溶剤脱脂後の性能も優れているため、家電メーカ
ーを中心に広く使用されている。
〔発明が解決しようとする課題〕
しかしながら、これらの方法により製造された表面処理
材は、樹脂皮膜層が金属素材と工具との間に介在するた
めに従来の表面処理材であるリン酸塩処理鋼材及びクロ
メート処理鋼材よりは成形加工性は優れているものの、
十分ではない、そのために、反応型クロメート処理をし
た後、樹脂コーティングをする方法、およびクロメート
含有水系樹脂をコーティングする方法のいずれの場合で
も、素材に予めプレス油などを塗布した後成形加工する
必要がある。そのために、−旦塗布したプレス油を脱脂
工程で除去し、次の塗装工程などへ移るという煩雑な工
程が必要であった。
本発明の目的は、上記の煩雑なプレス油塗布、その後の
除去といった工程を省略する為、クロメート含有水系樹
脂により形成される皮膜に潤滑性を付与し、プレス油な
どの塗布を必要としないで成形加工でき、加工後脱脂工
程を省きそのまま塗装しても塗膜密着性の優れた皮膜を
形成する金属表面処理組成物を開発することである。
[課題を解決するための手段] 本発明者らは種々の研究を重ねた結果、クロメート含有
水系樹脂に1種または2種以上のノニオン系乳化剤を使
用して分散した潤滑剤を固形分比で1重量%〜50重量
%配合することで良好な貯蔵安定性を有し、潤滑性、加
工成形性に優れた金属表面処理組成物を完成した。また
、この組成物は、耐食性、金属ならびに上塗り塗膜との
密着性に優れた皮膜を形成することも判明した。
すなわち、本発明は無機化合物として6価クロムイオン
又は6価クロムイオンと3価クロムイオン、及び有機化
合物として下記のアクリル系重合体エマルジョン、潤滑
成分としてノニオン系乳化剤で分散した1種または2種
以上の潤滑剤分散物1重量%〜50重量%(固形分比)
を含有し、pH5以下であり、クロメート含有水系樹脂
液に潤滑剤分散物を配合したことを特徴とする潤滑性に
優れた金属表面処理組成物を提供する。
アクリル系重合体エマルジョンは、 1)エチレン系不飽和カルボン酸単量体、2)(イ)下
記一般式で表されるアルコキシメチレン(メタ)アクリ
ルアミドとその誘導体 CH,=C−C0NH−CH,O−Y ただし、XはCnHx++++ (n=0またはl)Y
はC+aHam++(lI”0〜4 )(ロ)アシッド
ホスホオキシアルキル (メタ)アクリレート (ハ)アルコキシアルキル(メタ)アクリレート から選んだ1又は2以上の単量体、 3)アクリル系単量体(少なくとも一部が前記2)の(
ハ)からなることもある)から選んだ1又は2以上から
なり、所望によりこれらの共重合性単量体を含有する骨
格用単量体、 の前記1)、2)、3)を、実質的にアニオン性乳化剤
及びカチオン性乳化剤を含まず、ポリオキシエチレンー
ポリオキシブロビレンブロツクボリマー系乳化剤を含有
するノニオン性乳化剤を用いて乳化重合して得たアクリ
ル系重合体エマルジョンである。
以下、本発明について詳細に説明する。
本発明で有機化合物として使用するアクリル系重合体エ
マルジョンは、上記の1)、2)、3)の各群の単量体
を乳化共重合したものである。
以下、各群の単量体について説明する。
1)のエチレン系不飽和カルボン酸単量体とは不飽和モ
ノまたはジカルボン酸を指す。エチレン系不飽和カルボ
ン酸モノマーは、主として金属に対する密着性に寄与す
るカルボキシル基の供給源である。エチレン系不飽和カ
ルボン酸モノマーは、アクリル酸、メタクリル酸、クロ
トン酸、イタコン酸、マレイン酸あるいはフマール酸な
ど及びこれらのハーフエステルを含む。
2)の(イ)の下記一般式: %式% ただし、XはCnH2n++ (n”0またはl)Yは
CmH2,1,、I(11=0〜4)で表されるアルコ
キシメチレン(メタ)アクリルアミドとその誘導体とは
、n=oのときはアルコキシメチレンアクリルアミドで
あり、n=1のときはアルコキシメチレンメタクリルア
ミドであり、またm=oのときはメトキシメチレン(メ
タ)アクリルアミド、m=1のときはエトキシメチレン
(メタ)アクリルアミド、m = 2のときはブトキシ
メチレン(メタ)アクリルアミド、m=3のときはプロ
パノキシメチレン(メタ)アクリルアミド)、m=4の
ときはブトキシメチレン(メタ)アクリルアミドである
2)の(ロ)のアシッドホスホオキシアルキル(メタ)
アクリレートは、アシッドホスホオキシメチルアクリレ
ート、アシッドホスホオキシエチルアクリレート、アシ
ッドホスホオキシプロピルアクリレート、アシッドホス
ホオキシメチルメタクリレート、アシッドホスホオキシ
エチルメタクリレート、アシッドホスホオキシプロピル
メタクリレートなどを含む。
2)の(ハ)のアルコキシアルキル(メタ)アクリレー
トは、メトキシメチルアクリレート、メトキシエチルア
クリレート、メトキシメチルメタクリレート、メトキシ
エチルメタクリレート、エトキシメチルアクリレート、
エトキシエチルアクリレート、エトキシメチルメタクリ
レート、エトキシエチルメタクリレート、などを含む。
前記(イ)、(ロ)、(ハ)の単量体は、それぞれが有
するN−置換メチロール基(CH,=C−C0NH)リ
ン酸基、アルコキシル基により、本発明の組成物が形成
する金属表面処理皮膜と、その上に塗装した塗膜との密
着性向上に寄与する。したがって、(イ)、(ロ)、(
ハ)の少なくとも1群以上を使用すれば上記の効果が得
られる。
3)のアクリル系単量体は皮膜の骨格になるものであり
、メチルアクリレート、メチルメタクリレート、エチル
アクリレート、エチルメタクリレート、イソプロピルア
クリレート、イソプロピルメタクリレート、n−ブチル
アクリレート、n−ブチルメタクリレート、2−エチル
へキシルアクリレート、2−エチルへキシルメタクリレ
ート、オクチルアクリレート、オクチルメタクリレート
、アクリロニトリル、メタクリレートリル、アクリルア
ミド、メタクリルアミドなどを含むものであり、2)の
(ハ)のアルコキシアルキル(メタ)アクリレートも含
むものである。
なお、1)及び2)の(イ)(ロ)は塗膜の密着性に寄
与するが骨格にはならない。
また、所望により3)に含有させる、これらの共重合性
単量体は、スチレン、メチルスチレン、酢酸ビニル、α
位で分岐した飽和カルボン酸のビニルエステル、塩化ビ
ニル、ビニルトルエン、エチレンなどを含む。
したがって、3)には次の組合わせがある。
■、アクリル系単量体(ただし2)の(ハ)のアルコキ
シアルキル(メタ)アクリレートとは共通しない別種の
アクリル系単量体)、 ■、■+アルコキシアルキル(メタ)アクリレート(す
なわち一部が2)の(ハ)のアルコキシアルキル(メタ
)アクリレートと共通し、残部は共通しないアクリル単
量体) ■、アルコキシアルキル(メタ)アクリレート(すなわ
ち、2)の(ハ)と3)が同種)■、■十共重合性単量
体 ■、■+ ■、■+ 3)の単量体は、本発明で使用するアクリル系重合体エ
マルジョンの骨格を構成し、樹脂の硬軟、可撓性、強伸
度、弾性、粘着性、ガラス転移温度、最低造膜温度など
の物性及び化学的安定性などを支配する基本単量体であ
る。
しかして、アルコキシアルキル(メタ)アクリレートは
2)の単量体として密着性向上作用を有するとともに、
骨格単量体としても作用する特異な単量体であるため、
本発明の構成は、アルコキシアルキル(メタ)アクリレ
ートが2)と3)の両方に含まれることもある特殊な構
成とした。
従って、例えば、1)、2)、3)の単量体の組合わせ
の一つとして、アクリル酸−アルコキシアルキル(メタ
)クリレート−スチレンの組合せもあるが、得られたア
クリル系重合体エマルジョンは本発明で用いる有機化合
物として十分な効果を奏する。各有様化合物は特にその
量に制限はない。
本発明に使用するアクリル系重合エマルジョンの重合時
に使う乳化剤はノニオン性乳化剤であるが、そのノニオ
ン性乳化剤とは、ポリオキシエチレンアルキルエーテル
、ポリオキシエチレンアルキルフェノールエーテル、ポ
リオキシエチレンアルキルエステル、ソルビタンアルキ
ルエステル、ポリオキシエチレンソルビタンアルキルエ
ステル、ポリオキシエチレンーポリオキシブロビレンブ
ロックボリマーなどを含む。ノニオン性乳化剤に有意量
のイオン性の乳化剤が共存する場合は、ポリオキシエチ
レンーポリオキシブロビレンブロックボリマ−(EO−
POブロックポリマー)を用いたとしても、生成したエ
マルジョンのクロム酸混和安定性は著しく低下すること
からイオン性の乳化剤は併用すべきではない。
重合時に用いるノニオン性乳化剤としてポリオキシエチ
レンーポリオキシブロビレンブロックボリマー(EO−
POブロックポリマー)を用いることによりクロム酸と
の混和安定性が著しく優れたエマルジョンを得ることが
できる。ノニオン性乳化剤中にEO−POブロックポリ
マーが占める割合は好ましくは5重量%〜100重量%
の範囲にある。
EO−POブロックポリマーの割合を多くしていくと粗
大なエマルジョン粒子の生成が増加する傾向が認められ
るが、最終的に得られるエマルジョンの温度を低めに設
定することにより、EP−POブロックポリマー単独使
用による重合によっても粗大エマルジョンの生成を避け
ることが出来る。EO−POブロックポリマーのノニオ
ン性乳化剤中に占める割合は5重量%未満であるとクロ
ム酸との混和性は十分ではない。
本発明で無機化合物として使用する6価クロムイオンは
、クロム酸もしくはクロム酸塩化合物の形で組成物に供
給される。クロム酸は通常、無水クロム酸または無水ク
ロム酸の水溶液の形で、クロム酸塩はクロム酸または重
クロム酸のアンモニウム、カリウム、ストロンチウム、
バリウム、ナトリウム、亜鉛などの塩の形で供給するこ
とができる。
6価クロムイオンは強酸化剤であり、鋼、亜鉛、アルミ
ニウムなどの金属表面を不動態化し、金属を腐食から保
護する作用をもつ、また6価クロムイオンの一部は皮膜
形成時の乾燥工程での加熱のもとアクリル重合体エマル
ジョン中の乳化剤や樹脂中の官能基で還元され、3価ク
ロムイオンとなり、6価クロムの水難溶性化と樹脂の高
分子化に役立っている。
本発明において場合により使用する無機化合物の3価ク
ロムイオンは6価クロムイオンを含む水溶液にメタノー
ル、エタノール、しゅう酸、デンプン、過酸化水素、ピ
ロガロールなどの還元剤を加えて、6価クロムイオンを
部分還元することにより生成させることができる。また
は、炭酸クロム、水酸化クロムをクロム酸水溶液に溶解
させることによっても3価クロムイオンを供給すること
ができる。6価クロム、クロム酸は金属に対し防錆作用
を有するが、水に溶解し易い性質があり、金属表面上に
被膜として形成された後、被膜が水分と接触した際容易
に溶解して被膜中から離脱し、その結果被膜による防錆
効果が著しく失われるだけでな(6価クロムによる環境
汚染の問題を生ずるおそれがある。3価クロムは6価ク
ロム(クロム酸)と結合して水に難溶のクロム酸クロム
を形成し、6価クロムの膜中からの溶出を抑制すること
により防錆効果の維持と環境汚染防止の目的に寄与して
いる。従って硝酸クロム、硫酸クロム、塩化クロム、ク
ロムみょうばんなど対アニオンが組成液中に残る化合物
を用いるのは、被膜形成時に、3価クロムイオンの一部
ないしは大半が、これらのアニオンと結合して可溶性の
3価クロム化合物を形成し水に難溶であるクロム酸クロ
ムの生成量が、減少するので好ましくない。
3価クロムは、また樹脂中の官能基と結合してアクリル
重合体樹脂のクロスリンクによる高分子化をもたらし、
その結果、金属上に形成された被膜の耐アルカリ脱脂性
を向上させる。
アクリル系重合体エマルジョン樹脂と6価クロムイオン
及び3価クロムイオンとの比率は樹脂/全クロム=20
0〜0.2であることが好ましい。この比が200を超
えると耐アルカリ性が不十分となり、形成された皮膜の
アルカリ脱脂後の耐食性及び上塗り塗料との塗膜密着性
が低下する。この比が0.2未満であると形成された皮
膜にアクリル系重合体エマルジョン樹脂の効果が不十分
となり、十分な耐水性、耐アルカリ性、上塗り塗料との
塗膜密着性が得られない。
6価クロムイオンと3価クロムイオンとの比率は、リン
酸などの他の酸を含まない場合、薬剤の安定性の面でC
r”″/Cr”が1以下であることが好ましく、またリ
ン酸などの酸を含有する場合でも6価クロムの耐食性を
十分に期待するためにはCr ”/ Cr ’″″が5
以下であることが好ましい。
本発明に用いるアクリル系重合エマルジョン、クロム酸
及び潤滑剤を必須成分とする組成物はpH5以下で使用
されるべきであり、また潤滑剤分散物添加前のクロメー
ト含有水系樹脂のpHも5以下でなければならない。p
Hが5を超えると上塗り塗料の密着性が不良となり、又
本発明による表面処理皮膜と素地金属との密着性が低下
するため、該皮膜が深絞り加工時に剥離を生じ、潤滑特
性も不良になる。本発明に示すモノマー組成の重合エマ
ルジョンを未中和で用いれば、組成物のpHは5以下と
なるが、5を超えたときにはクロム酸又はリン酸を用い
て調整することができる。
本発明で使用する潤滑剤は、成形加工の際の摩擦抵抗を
下げる作用を持ち、また、成形加工時に発生する熱のた
め一部融解し成形物と金型との間の焼付きを防止する作
用を持っている。このような潤滑剤としてはそれ自体公
知のものが使用できる。下記に潤滑剤を例示する。
炭化水素滑剤類:例えば天然パラフィン、合成パラフィ
ン、マイクロワックス、ポリエチレンワックス、塩素化
炭化水素、フルオロカーボンなど。
脂肪酸系滑剤:ラウリン酸、ステアリン酸、パルミチン
酸、オキシ脂肪酸など。
脂肪酸アミド系滑剤:例えばステアリン酸アミド、パル
ミチン酸アミド、メチルビスステアロアミド、エチレン
ビスステアロアミド、オレイン酸アミド、エシル酸アミ
ド、アルキレンビス脂肪酸アミドなと。
エステル系滑剤:例えばブチルステアレートのような脂
肪酸の低級アルコールエステル、硬化ヒマシ油などのよ
うな脂肪酸の多価アルコールエステル、エチレングリコ
ールモノステアレートのような脂肪酸のグリコールエス
テルまたはポリグリコールエステル、エステルワックス
など。
アルコール系滑剤:例えばセチルアルコール、ステアリ
ルアルコール、パルミチルアルコールなど。
金属石けん類:例えばステアリン酸カルシウム、ステア
リン酸鉛、ラウリン酸カルシウム、バルミチン酸カルシ
ウムなど。
金属硫化物類二二硫化モリブデン、二硫化タングステン
など。
含ふっ素ポリマー:ポリテトラフルオロエチレン、ポリ
トリフルオロエチレン、ポリふっ化ビニリデン、ポリふ
っ化ビニルなど。
その他:グラファイト、ふっ化黒鉛、窒化ホウ素など。
これらの潤滑剤を分散するためにノニオン系乳化剤のみ
が使用できる。カチオン、アニオン及び両性乳化剤を使
用した場合、分散した潤滑剤のクロメート含有水系樹脂
への混合性が劣る。ノニオン系乳化剤としてはポリオキ
シエチレンアルキルエーテル、ポリオキシエチレンアル
キルフェノールエーテル、ポリオキシエチレンアルキル
エステル、ソルビタンアルキルエステル、ポリオキシエ
チレンソルビタンアルキルエステル、ポリオキシエチレ
ンーポリオキシブロビレンブロックボリマー、及びパー
フロロアルキルオキシエチレン付加物などが使用できる
。乳化剤の使用量は分散する潤滑剤に対し1〜20重量
%が好ましい。乳化剤の量が潤滑剤に対し1重量%未満
では沈降や沈殿を起こしやすく、又起こさない場合でも
、クロム含有水系樹脂と混合した場合凝集などが起こり
、混和安定性が劣る。一方、乳化剤の量が20重量%を
超えた場合、形成された皮膜の耐水性、耐アルカリ性な
どが低下する。これらの潤滑剤は単独でも使用できるが
、2種以上併用することによってさらに潤滑性を向上さ
せることができる。
潤滑剤は適量の水、好ましくは脱イオン水中に乳化剤を
用いて分散させる。
潤滑剤の配合量は本発明組成物中固形分で1〜50重量
%である。特に5〜40重量%が好ましい。配合量が1
重量%以下では潤滑性が十分でなく、又51重量%以上
では形成された皮膜の強度、素地金属に対する密着性が
低下し、潤滑性、耐食性、耐アルカリ性、耐溶剤性、塗
膜密着性などが低下する。
本発明の実施態様において表面処理組成物に添加される
リン酸イオンはオルソリン酸のような酸、リン酸アンモ
ニウム、リン酸ナトリウム、リン酸カリウムのようなア
ルカリリン酸塩、リン酸カルシウム、リン酸マグネシウ
ムのようなアルカリ土類リン酸塩、リン酸亜鉛、リン酸
マンガン、リン酸ニッケル、リン酸コバルト、リン酸ア
ルミニウムなどの金属リン酸塩の形で供給できる。これ
らのリン酸イオンは本発明の組成物の皮膜形成時に6価
クロムイオンによるエマルジョン樹脂成分による還元を
容易にすると同時に、3価クロムと化合して難溶性塩を
形成し皮膜の耐アルカリ性、耐食性を向上させることが
できる。
また、本発明の別の実施態様において表面処理組成物に
添加されるシリカは1次粒径が5μm〜100μmの大
きさの微粒子状のシリカを使用でき、その製法は気相法
、液相法のいずれでもよい。シリカはその表面に6価ク
ロムを吸着、固定化し、6価クロムの溶出を抑制するこ
とにより皮膜の耐食性を向上させる。
本発明の別の実施態様において表面処理組成物に添加さ
れるコバルト、ニッケル、マンガン、亜鉛などの重金属
は、これらの金属イオンが皮膜形成時にクロム酸と結合
して水に難溶なりロム酸重金属塩を形成するので、プレ
ス様による加工中の汚れを除去する等のためにをアルカ
リ脱脂する時に6価クロムの溶出を低減させることによ
って耐食性を向上する。これらの重金属イオンは炭酸塩
、水酸化物、酸化物またはリン酸塩で供給することが望
ましい。硫酸塩、塩化物、硝酸塩などこれらの金属イオ
ンと可溶性の塩を形成するアニオンとの化合物は、これ
らの金属イオンとクロム酸との難溶性塩の形成を阻害す
るので好ましくない。本発明の別の実施態様において表
面処理組成物に添加されるフッ素イオンは皮膜形成時に
金属表面の活性化に寄与し、金属素地と皮膜の密着性ひ
いては金属と塗膜との密着性を改善する。フッ素イオン
はフッ化水素酸、ジルコンフッ化水素酸、珪フッ化水素
酸、チタンフッ化水素酸、硼フッ化水素酸及びこれらの
酸のアンモニウム塩、リチウム塩、ナトリウム塩、カリ
ウム塩などのフッ素化合物の形で添加することができる
次に、これら四つの添加物の添加量についてであるが、
リン酸イオンはP04/全Cr重量比で0.05〜5、
シリカ微粒子は5iOa/全Cr重量比で0.1〜10
、フッ素化合物はF/全Cr重量比で0.01〜0.5
、の範囲が適当であり、この範囲から外れると添加の効
果が余りない。コバルト、ニッケル、亜鉛、マンガンの
金属イオンの場合これらの金属イオンと3価クロムイオ
ンの合計したダラム当量がクロム酸とリン酸と合計した
ダラム当量との比(金属イオン+Cr”/((:r04
”−+po、”−)≦0.5でなければ、組成物中に沈
殿が生しることがあるのでこの範囲内が望ましい。
本発明の組成物が塗布される素材としては鉄、アルミニ
ウム、亜鉛、錫、銅及びこれら金属の合金類(合金元素
として、例えば亜鉛、アルミニウム、クロム、ケイ素、
コバルト、ジルコニウム、錫、チタン、鉄、鉛、ニッケ
ル、マグネシウム、マンガン、モリブデン、リンなどの
一種又は二種以上が添加される)が対象になり、さらに
これら金属素材のめっき材、ならびにこれら金属素材及
びそのめっき材のクロメート処理材、リン酸塩処理材、
陽極処理材なども対象になる。処理対象になる形状は、
板状、コイル状、棒状、線状などである。これらの形状
の金属素材に組成物を塗布する塗装方法は例えばはけ塗
り、スプレー塗り、ロール塗り、シャワー塗り、浸漬塗
りなどが適用できる。塗布後の乾燥・硬化方法としては
熱風炉、赤外線炉、高周波炉などが使用できる。
本発明の金属処理組成物処理の指標を例として表面処理
鋼板の製造について以下説明する。
本発明の金属処理組成物を亜鉛めっき鋼板、冷延鋼板、
アルミニウム板などの金属板上に塗布したときの好まし
いクロム付着量は 1〜500mg/m2、更に好まし
くは5〜300 mg/m”の範囲である。クロム付着
量は1 mg/m”未満では十分な耐食性かえられず、
500 mg/m”を越えるとCrによる着色が著しく
、商品価値が劣化する。
同じく好ましい樹脂の付着量は10〜2000mg/m
” 、更に好ましくは50〜1500mg/m”の範囲
である。10 mg/m”未満では潤滑性、耐食性、耐
指紋性、塗膜密着性において樹脂の効果が十分とは言え
ない。樹脂の付着量が3000 B/m3を越しても耐
食性、耐指紋性、塗膜密着性は向上しないばかりか、溶
接性が低下するため溶接加工をする用途には適していな
い皮膜となる。
また、本発明の組成物中の3価クロムとアクリル重合体
樹脂とのクロスリンクには到達板温で80℃以上必要で
あるが、この乾燥・硬化条件は現存の表面処理鋼板ライ
ンで十分対応できる。
〔作用〕
クロメート含有水系樹脂は強酸かつ強酸化剤であるクロ
ム酸を含有している為、潤滑剤が有機化合物の場合凝集
作用と酸化作用を受け、配合した塗工剤が沈殿、凝集、
増粘ゲル化などの現象を起こしやすい。又クロメート含
有水系樹脂に潤滑剤を添加すると塗装後の塗膜密着性等
が低下する問題がある。本発明は、クロメート含有水系
樹脂に潤滑剤をいかに安定に分散させ、形成した皮膜に
優れた潤滑性、耐食性、塗装性を有する金属表面処理組
成物を実現するかにつき研究し、ノニオン系乳化剤を使
用して潤滑剤を分散させること;か(して得られた分散
系をアクリル系重合体エマルジョンと混合すること;が
有効であることを見出した。
〔発明の効果〕
上記のように塗装・乾燥して形成した本発明の組成物の
皮膜は潤滑性に優れているため、一般的な加工度の成形
品についてはプレス油などの塗布なしに表面処理材をそ
のまま、金型の摩耗、板切れもなく、深絞り加工などの
プレス成形加工することができる。また、極めて過酷な
特殊なプレス加工を行う場合は、本発明の表面処理皮膜
による成形性のみでは不充分なこともあるので、プレス
油を使用せざるをえないが、この場合でも本発明の皮膜
の潤滑性の効果は発揮される。
また、本発明の表面処理皮膜はアルカリ脱脂、溶剤脱脂
(トリクロロエタンなど)に対しても優れた耐脱脂性を
示し、脱脂前後による前述性能の差がほとんどない。し
たがって、金属素材の製造、取扱い、保管中に生じた汚
れを脱脂してからプレス加工を行う際にも、すぐれた成
形性が発揮される。
同時に本発明の表面処理皮膜は金属を防食する耐食性、
金属に対する密着性も優れている。これらの性能が優れ
ているために、処理材を長期間保管した状態においても
金属の腐食が起こらず、また下地素材の腐食や皮膜の剥
離等により、潤滑剤が脱落し、潤滑性が劣化することも
避けられる。
以下本発明の実施例を示す。
〔実施例〕
アクリル系重合体エマルジョンの製造例1:次の方法に
よりアクリル系重合体エマルジョンを得た。
A)モノマー乳化液組成 イオン交換水       150重量部エマルゲン8
403I116 プロノン120g”+         2メタクリル
酸        4 メトキシメチレンアクリル アミド   2重量部 n−ブチルアクリレート    82 メチルメタクリレート   112 B)4ツロフラスコへの仕込み組成 イオン交換水       116重量部エマルゲン8
40S        4プロノン1208     
   4 C)重合開始剤 5%過過硫酸アンシン水溶液10重量部5%酸性亜鉛硫
酸ソーダ水溶液 10重量部 1ポリオキシエチレンオクチルフエニルエーテルの70
%水溶液(花王石鹸 (株)製、ノニオン性乳化剤) 2′ポリオキシエチレンーポリオキシブロビレンブロツ
クボリマー(日本油脂 (株)製、ノニオン性乳化剤) (重合法) 容量ILの撹拌装置を備えた4つ口のフラスコに、B)
を仕込んで加温溶解し40℃に保つ、別に容量0.5L
の共栓付き三角フラスコにA)を仕込んでモノマー乳化
液を作り、その10%を、5%過過硫酸アンシン水溶液
び5%酸性亜硫酸ソーダ水溶液各25%に加えて、40
〜50℃で15〜20分間重合を行う。次いで、A)の
残り90%と、重合開始剤の各々の残り75%を40℃
〜50℃において3時間かけて滴下する。滴下終了後4
0〜50℃で1時間保持して重合を完結する。得られた
エマルジョンは濃度43%、粘度300cp、 pH2
,2であった。
アクリル系重合体エマルジョンの製造例2〜4: (製
造例:3.4は比較製造例) 製造例1において、モノマー組成及び乳化剤を第1表の
ように変えて重合して、アクリル系重合体エマルジョン
を得た。
潤滑剤の分散例1: 次の方法により潤滑剤の乳化物を得た。
パラフィンワックス(日木精蝋株式会社製、品名155
)40重量部を融点まで加熱し、これにインルビタンモ
ノステアラード2重量部、ポリオキシエチレンステアリ
ルエーテル3重量部を加え一緒に溶融した。溶融物を9
7℃に保ちながら、95〜99℃の脱イオン水55重量
部を撹拌下(回転数=10Orpm)で10分間にわた
り添加した。添加後、ワックス−脱イオン水系混合液を
撹拌下(回転数=2Orpm)で放冷し、室温にもどし
た。ワックスの濃度を脱イオン水で調整、濃度40重量
%のパラフィンワックス乳化物を得た。潤滑剤分散物の
分散例2〜12(乳化例8〜12は比較乳化例): 潤滑剤の分散例1において潤滑剤及び乳化剤を第2表の
ように変え、潤滑剤分散物を得た。
実施例1〜12ニ アクリル系重合体エマルジョンの製造例1.2で得たア
クリル系重合体エマルジョンと6価クロム(Cr Om
を用いた)又はそれに3価クロム(メタノールで6価ク
ロムを部分還元した)などの無機化合物と、潤滑剤の分
散例1〜7で得た潤滑剤乳化物とを混合し、第3表に示
す内容の本発明による金属表面処理組成物を得た。これ
らの組成物を清浄な電気亜鉛めっき鋼板(めっき目付量
= 20 g/m”)に乾燥皮膜量が1 g/m”とな
るようロールで塗布し、到達板温が100℃となるよう
に熱風で乾燥し供試材とした0本発明による金属表面処
理組成物の安定性、及び供試材の性能試験結果を第3表
に示す。
比較例1〜11: 製造例3.4で得たアクリル系重合体エマルジョン、及
び潤滑剤の分散例8〜12、及び6価クロム、3価クロ
ムなどの無機化合物とを混合し、第3表に示す内容の金
属表面処理組成物を比較例として得た。これらの組成物
を上記方法と同様の方法で塗布・乾燥し、比較組成物の
処理材とした。比較組成物の安定性、及び処理材の性能
試験結果を第3表に示す。
試験方法、及び評価基準 1、安定性 金属表面処理組成物を40℃の恒温条件に置き、ゲル化
するまでの日数を観察した。
○−30日以上、△−7日以上30日未満、×−7日未
満 2、未塗装板耐食性 本発明実施例及び比較の供試材をさらに塗料で塗装する
ことなく塩水噴霧試験(JIS−Z−2371)を14
4時間実施し、発錆面積を測定した。
〇−発錆面積:5%未満、△−発錆面積:5〜30%、
×−発錆面積:31%以上 3、塗装板耐食性 供試材、比較材に焼付型メラミンアルキッド塗料を塗装
(塗膜厚は20±2μm)し、この塗膜に素地金属まで
達するきすをカッターで入れ、塩水噴霧試験を200時
間実施した。実施後テープ剥離し、きずからの平均両側
剥離中を測定して、塗装板耐食性を評価した。
〇−剥離なし、〇−剥離巾=0.1〜3.0m/m、X
−3,1m/m以上 4、塗膜密着性 上記塗板に1mm四方100個のますを刻み、エリクセ
ン試験機で5mm押し出した後、テープ剥離し塗膜の残
存する目数を測定した。
〇−残存目数=90〜100、×−残存目数=89以下 5、深絞り性 ブランク径:961DQlφ、ポンチ:40+amφ、
しわ押え圧:1.0tonの条件で円筒深絞り試験を実
施した。
〇−絞り抜け、皮膜のビルドアップなどの異常が観察さ
れない。
×−絞り抜けず。
尚、上記試験中1〜4は本発明実施例の供試材及び比較
材のアルカリ脱脂前後の2通りで実施した。アルカリ脱
脂は中アルカリ脱脂剤(日本バー力ライジング製パルク
リーンN−364S)を濃度二0.2%で使用し、液温
=60〜65℃、スプレー圧0 、8 kg/cm”で
2分間スプレー洗浄した。
第1表 製造したアクリル系重合体重フルジョンの千77−1乳
化剤

Claims (3)

    【特許請求の範囲】
  1. 1.無機化合物として6価クロムイオン又は6価クロム
    イオンと3価クロムイオン、及び有機化合物として下記
    のアクリル系重合体エマルジョン、潤滑成分としてノニ
    オン系乳化剤で分散した1種または2種以上の潤滑剤分
    散物1重量%〜50重量%(固形分比)を含有し、pH
    5以下であり、クロメート含有水系樹脂液に潤滑剤分散
    物を配合したことを特徴とする潤滑性に優れた金属表面
    処理組成物。 1)エチレン系不飽和カルボン酸単量体、 2)(イ)下記一般式で表されるアルコキシメチレン(
    メタ)アクリルアミドとその誘 導体 ▲数式、化学式、表等があります▼ ただし、XはC_nH_2_n_+_1(n=0または
    1)YはC_mH_2_m_+_1(m=0〜4)(ロ
    )アシッドホスホオキシアルキル (メタ)アクリレート (ハ)アルコキシアルキル(メタ)アク リレート から選んだ1又は2以上の単量体、 3)アクリル系単量体(少なくとも一部が前記2)の(
    ハ)からなることもある)から選んだ1又は2以上から
    なり、所望によりこれらの共重合性単量体を含有する骨
    格用単量体、 の前記1)、2)、3)を、実質的にアニオン性乳化剤
    及びカチオン性乳化剤を含まず、ポリオキシエチレン−
    ポリオキシプロピレンブロックポリマー系乳化剤を含有
    するノニオン性乳化剤を用いて乳化重合して得たアクリ
    ル系重合体エマルジョン。
  2. 2.無機化合物として、さらに(イ)リン酸イオン、(
    ロ)シリカならびに(ハ)コバルト、ニッケル、マンガ
    ン、亜鉛の1種以上の金属イオンからなる群(イ)、(
    ロ)、(ハ)の1種以上が含まれている請求項1項記載
    の潤滑性に優れた金属表面処理組成物。
  3. 3.無機化合物として、さらにフッ素イオンが含まれて
    いる請求項1又は2記載の潤滑性に優れた金属表面処理
    組成物。
JP2011747A 1990-01-23 1990-01-23 潤滑性に優れた金属表面処理組成物 Pending JPH03219086A (ja)

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JP2011747A JPH03219086A (ja) 1990-01-23 1990-01-23 潤滑性に優れた金属表面処理組成物
CN91100513A CN1043242C (zh) 1990-01-23 1991-01-23 具有优良润滑性的金属表面处理组合物
KR1019910001103A KR930007152B1 (ko) 1990-01-23 1991-01-23 윤활성에 뛰어난 금속표면처리 조성물
US08/061,341 US5378291A (en) 1990-01-23 1993-05-17 Coating composition for metal

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Publication Number Publication Date
JPH03219086A true JPH03219086A (ja) 1991-09-26

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US (1) US5378291A (ja)
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH04272844A (ja) * 1991-02-27 1992-09-29 Yodogawa Steel Works Ltd 被覆表面処理金属板
JPH08253873A (ja) * 1995-03-15 1996-10-01 Nippon Parkerizing Co Ltd 金属材料用潤滑性クロメート処理組成物、および処理方法
WO1996036748A1 (fr) * 1995-05-18 1996-11-21 Nippon Steel Corporation Toles metalliques traitees par resine-chromate et reduites par lessivage du chrome
WO1997046733A1 (en) * 1996-06-06 1997-12-11 Sumitomo Metal Industries, Ltd. Surface-treated steel sheet excellent in corrosion resistance after working
JPH1060315A (ja) * 1996-08-14 1998-03-03 Nippon Parkerizing Co Ltd 亜鉛系めっきを施した鋼材もしくは鋼構造物用の表面処理剤
WO1999063012A1 (fr) * 1998-06-01 1999-12-09 Nihon Parkerizing Co., Ltd. Agent de traitement de surface a base aqueuse
WO2010087442A1 (ja) * 2009-01-30 2010-08-05 ユケン工業株式会社 化成処理のための組成物およびその組成物による化成皮膜を備える部材
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WO1999063012A1 (fr) * 1998-06-01 1999-12-09 Nihon Parkerizing Co., Ltd. Agent de traitement de surface a base aqueuse
WO2010087442A1 (ja) * 2009-01-30 2010-08-05 ユケン工業株式会社 化成処理のための組成物およびその組成物による化成皮膜を備える部材
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JP4665137B2 (ja) * 2009-01-30 2011-04-06 ユケン工業株式会社 化成処理のための組成物およびその組成物による化成皮膜を備える部材
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JP2020059873A (ja) * 2018-10-09 2020-04-16 サイデン化学株式会社 金属表面処理用樹脂エマルション、金属表面処理剤、表面処理金属材及びその製造方法、並びに樹脂エマルションの製造方法

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