U.S. patent application number 10/816988 was filed with the patent office on 2004-11-04 for electrolytic and electroless process for treating metallic surfaces and products formed thereby.
Invention is credited to Haran, Bala, Heimann, Robert L., Popov, Branko, Slavkov, Dragan.
Application Number | 20040217334 10/816988 |
Document ID | / |
Family ID | 23200590 |
Filed Date | 2004-11-04 |
United States Patent
Application |
20040217334 |
Kind Code |
A1 |
Heimann, Robert L. ; et
al. |
November 4, 2004 |
Electrolytic and electroless process for treating metallic surfaces
and products formed thereby
Abstract
The disclosure relates to an electroless or electrolytic process
for treating metallic surfaces. The process employs a medium
comprising at least one oxygen containing water soluble compound
(e.g., stannates, molybdates, vanadates and hydrated cerium
compounds) having a controlled and predetermined concentration,
temperature and pH wherein the metallic surface is at least
partially corroded or solubilized.
Inventors: |
Heimann, Robert L.;
(Centralia, MO) ; Popov, Branko; (Columbia,
SC) ; Slavkov, Dragan; (Columbia, SC) ; Haran,
Bala; (Columbia, SC) |
Correspondence
Address: |
ORSCHELN MANAGEMENT CO
2000 US HWY 63 SOUTH
MOBERLY
MO
65270
US
|
Family ID: |
23200590 |
Appl. No.: |
10/816988 |
Filed: |
April 1, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10816988 |
Apr 1, 2004 |
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10211029 |
Aug 2, 2002 |
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6753039 |
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60310006 |
Aug 3, 2001 |
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Current U.S.
Class: |
252/500 |
Current CPC
Class: |
C23C 22/62 20130101;
C23C 22/60 20130101 |
Class at
Publication: |
252/500 |
International
Class: |
C25D 005/18 |
Claims
1. A method for treating a substrate having an electrically
conductive surface comprising: contacting at least a portion of the
surface with a medium comprising at least one oxygen containing
water soluble and having a basic pH and wherein said medium is
substantially free of chromates, drying the substrate, rinsing the
substrate, and; again drying the substrate.
2. An aqueous medium for use in increasing the electrical
resistance of a conductive surface comprising a combination
comprising water, at least one member selected from the group of
water soluble stannates, molybdates, vanadates and hydrated cerium
compounds, wherein the medium has a basic pH and is substantially
free of chromates.
3. The medium of claim 2 wherein said medium further comprises
colloidal silica.
4. The method of claim 1 wherein the surface comprises at least one
member selected from the group consisting of copper, nickel, tin,
iron, zinc, aluminum, magnesium, stainless steel and steel and
alloys thereof.
5. The method of claim 1 wherein said drying is conducted at a
temperature of at least about 120 C.
6. The method of claim 1 further comprising applying at least one
coating upon the last dried surface.
7. The method of claim 1 further comprising applying an adherent
composition comprising at least one member chosen from the group of
latex, silanes, epoxies, silicone, amines, alkyds, urethanes and
acrylics.
8. The method of claim 1 wherein said medium comprises the medium
of claim 2.
9. The method of claim 1 wherein said medium comprises the medium
of claim 3.
10. The medium of claim 2 wherein said water soluble compounds
comprise at least one member selected from the group consisting of
sodium stannate hydrate, sodium molybdate hydrate, ammonium
metavanadate and cerium nitrate hydrate.
11. The method of claim 1 wherein the pH is sufficient to at least
partially dissolve the surface.
Description
[0001] The subject matter herein claims benefit of prior filed U.S.
Patent Application Ser. No. 60/310,006, filed on Aug. 3, 2001 and
entitled "An Electrolytic And Electroless Process For Treating
Metallic Surfaces and Products Formed Thereby"; the disclosure of
which is hereby incorporated by reference.
CROSS REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS
[0002] The subject matter of the instant invention is related to
copending and commonly assigned WIPO Patent Application Publication
No. WO 98/33960, Non-Provisional U.S. patent application Ser. No.
08/850,323 (Now U.S. Pat. No. 6,165,257); Ser. No. 08/850,586 (Now
U.S. Pat. No. 6,143,420); and Ser. No. 09/016,853 (now allowed),
filed respectively on May 2, 1997 and Jan. 30, 1998; and Ser. No.
08/791,337 (now U.S. Pat. No. 5,938,976), filed on Jan. 31, 1997,
in the names of Robert L. Heimann et al., as a continuation in part
of Ser. No. 08/634,215 (filed on Apr. 18, 1996) in the names of
Robert L. Heimann et al., and entitled "Corrosion Resistant Buffer
System for Metal Products", which is a continuation in part of
Non-Provisional U.S. patent application Ser. No. 08/476,271 (filed
on Jun. 7, 1995) in the names of Heimann et al., and corresponding
to WIPO Patent Application Publication No. WO 96/12770, which in
turn is a continuation in part of Non-Provisional U.S. patent
application Ser. No. 08/327,438 (filed on Oct. 21, 1994), now U.S.
Pat. No. 5,714,093.
[0003] The subject matter of this invention is related to
Non-Provisional patent application Ser. No. 09/016,849 (Attorney
Docket No. EL004RH-1), filed on Jan. 30, 1998 and entitled
"Corrosion Protective Coatings". The subject matter of this
invention is also related to Non-Provisional patent application
Ser. No. 09/016,462 (Attorney Docket No. EL005NM-1), filed on Jan.
30, 1998 and entitled "Aqueous Gel Compositions and Use Thereof"
(now U.S. Pat. No. 6,033,495).
[0004] The subject matter of this invention is also related to
Non-Provisional patent application Ser. No. 09/814,641 (Attorney
Docket No. EL008RH-6), filed on Mar. 22, 2001, and entitled "An
Energy Enhanced Process For Treating A Conductive Surface And
Products Formed Thereby" (and corresponds to PCT Patent Application
Serial No. PCT/US01/09293), and Non-Provisional patent application
Ser. No. ______ (Attorney Docket No. EL022RH-1), filed on Aug. 3,
2002 and entitled "An Electroless Process For Treating Metallic
Surfaces And Products Formed Thereby", and Ser. No. ______
(Attorney Docket No. EL021RH-1), filed on Aug. 3, 2002 and entitled
"An Electroless Process For Treating Metallic Surfaces And Products
Formed Thereby".
[0005] The disclosure of the previously identified patents, patent
applications and publications is hereby incorporated by
reference.
FIELD OF THE INVENTION
[0006] The instant invention relates to a process for forming a
deposit on the surface of a metallic or conductive surface. The
process employs a process to deposit, for example, a mineral
containing coating or film upon a metallic, metal containing or an
electrically conductive surface.
BACKGROUND OF THE INVENTION
[0007] Silicates have been used in electrocleaning operations to
clean steel, tin, among other surfaces. Electrocleaning is
typically employed as a cleaning step prior to an electroplating
operation. Usage of silicates as cleaners is described in
"Silicates As Cleaners In The Production of Tinplate" is described
by L. J. Brown in February 1966 edition of Plating; European Patent
No. 00536832/EP B1 (Metallgesellschaft AG); U.S. Pat. Nos.
5,902,415, 5,352,296 and 4,492,616.
[0008] Processes for electrolytically forming a protective layer or
film by using an anodic method are disclosed by U.S. Pat. No.
3,658,662 (Casson, Jr. et al.), and United Kingdom Patent No.
498,485.
[0009] U.S. Pat. No. 5,352,342 to Riffe, which issued on Oct. 4,
1994 and is entitled "Method And Apparatus For Preventing Corrosion
Of Metal Structures" that describes using electromotive forces upon
a zinc solvent containing paint; hereby incorporated by reference.
U.S. Pat. No. 5,700,523, and 5,451,431; and German Patent No.
93115628 describes a processes for using alkaline metasilicates to
treat metallic surfaces.
[0010] The disclosure of each of the previously identified
references is hereby incorporated by reference.
SUMMARY OF THE INVENTION
[0011] The instant invention solves problems associated with
conventional practices by providing an electroless or electrolytic
process for treating metallic surfaces. The process employs a
medium comprising at least one oxygen containing water soluble
compound having a controlled and predetermined concentration,
temperature and pH wherein the metallic surface is at least
partially corroded or solubilized. As a result, the medium
interacts with the metallic surface to form a new or modified
surface having one or more improved properties.
[0012] The inventive process can form a surface comprising a
mineral layer comprising an amorphous matrix surrounding or
incorporating crystals upon the substrate. The characteristics of
the mineral layer are described in greater detail in the copending
and commonly assigned patent applications listed below.
[0013] A metallic surface that is treated (e.g., forming the
mineral layer) by the inventive process can possess improved
corrosion resistance, increased electrical resistance, heat
resistance, flexibility, resistance to stress crack corrosion,
adhesion to sealer, paints and topcoats, among other properties.
The improved heat resistance broadens the range of processes that
can be performed subsequent to forming the inventive layer, e.g.,
heat cured topcoatings, stamping/shaping, riveting, among other
processes. The corrosion resistance can be improved by adding a
dopant to the silicate medium, using a rinse and/or applying at
least one sealer/topcoating.
[0014] The inventive process is a marked improvement over
conventional methods by obviating the need for solvents or solvent
containing systems to form a corrosion resistant layer, e.g., a
mineral layer. In contrast, to conventional methods the inventive
process can be substantially solvent free. By "substantially
solvent free" it is meant that less than about 5 wt. %, and
normally less than about 1 wt. % volatile organic compounds
(V.O.C.s) are present in the electrolytic environment.
[0015] The inventive process is also a marked improvement over
conventional methods by reducing, if not eliminating, chromate
and/or phosphate containing compounds (and issues attendant with
using these compounds such as waste disposal, worker exposure,
among other undesirable environmental impacts). While the inventive
process can be employed to enhance chromated or phosphated
surfaces, the inventive process can replace these surfaces with a
more environmentally desirable surface. The inventive process,
therefore, can be "substantially chromate free" and "substantially
phosphate free" and in turn produce articles that are also
substantially chromate (hexavalent and trivalent) free and
substantially phosphate free. The inventive process can also be
substantially free of heavy metals such as chromium, lead, cadmium,
barium, among others. By substantially chromate free, substantially
phosphate free and substantially heavy metal free it is meant that
less than 5 wt. % and normally about 0 wt. % chromates, phosphates
and/or heavy metals are present in a process for producing an
article or the resultant article.
DETAILED DESCRIPTION
[0016] The instant invention relates to a process for depositing or
forming a beneficial surface (e.g., a mineral containing coating or
film) upon a metallic surface. The process contacts at least a
portion of a metal surface with a medium comprising at least one
oxygen containing water soluble compound, e.g., containing soluble
mineral components or precursors thereof, having controlled
concentration, temperature and pH wherein the metal surface is at
least partially corroded or solubilized. By "oxygen containing
water soluble compound" it is meant to refer to at least one member
selected from the group of borates, aluminates, zironcates,
titanates, molybdates, tungstenates, stannates, nitrates, sulfates,
vanadates, cerium hydrates, water soluble manganese and magnesium
compounds, nickel compounds, cobalt compounds, among other
oxygenated water soluble compounds capable of interacting with a
metal surface. By "mineral containing coating", "mineralized film"
or "mineral" it is meant to refer to a relatively thin coating or
film which is formed upon a metal surface wherein at least a
portion of the coating or film comprises at least one metal
containing mineral, e.g., an amorphous phase or matrix surrounding
or incorporating crystals comprising a zinc disilicate. Mineral and
Mineral Containing are defined in the previously identified
Copending and Commonly Assigned Patents and Patent Applications;
incorporated by reference.
[0017] By "metal containing", "metal", or "metallic", it is meant
to refer to sheets, shaped articles, fibers, rods, particles,
continuous lengths such as coil and wire, metallized surfaces,
among other configurations that are based upon at least one of
metals and alloys including a metal having a naturally occurring,
or chemically, mechanically or thermally modified surface.
Typically a naturally occurring surface upon a metal will comprise
a thin film or layer comprising at least one oxide, hydroxides,
carbonates, sulfates, chlorides, among others. The naturally
occurring surface can be removed or modified by using the inventive
process.
[0018] The metal containing surface refers to a metal article or
body as well as a non-metallic member having an adhered metal or
conductive layer. While any suitable surface can be treated by the
inventive process, examples of suitable metal surfaces comprise at
least one member selected from the group consisting of galvanized
surfaces, sheradized surfaces, zinc, iron, steel, brass, copper,
nickel, tin, aluminum, lead, cadmium, magnesium, alloys thereof
such as zinc-nickel alloys, tin-zinc alloys, zinc-cobalt alloys,
zinc-iron alloys, among others. If desired, the mineral layer can
be formed on a non-conductive substrate having at least one surface
coated with a metal, e.g., a metallized polymeric article or sheet,
ceramic materials coated or encapsulated within a metal, among
others. Examples of metallized polymer comprise at least one member
selected from the group of polycarbonate, acrylonitrile butadiene
styrene (ABS), rubber, silicone, phenolic, nylon, PVC, polyimide,
melamine, polyethylene, polyproplyene, acrylic, fluorocarbon,
polysulfone, polyphenyene, polyacetate, polystyrene, epoxy, among
others. Conductive surfaces can also include carbon or graphite as
well as conductive polymers (polyaniline for example).
[0019] The metal surface can possess a wide range of sizes and
configurations, e.g., fibers, coils, sheets including perforated
acoustic panels, chopped wires, drawn wires or wire strand/rope,
rods, couplers (e.g., hydraulic hose couplings), fibers, particles,
fasteners (including industrial and residential hardware),
brackets, nuts, bolts, rivets, washers, cooling fins, stamped
articles, powdered metal articles, among others. The limiting
characteristic of the inventive process to treat a metal surface is
dependent upon the ability of the surface to be contacted with the
inventive medium.
[0020] The inventive process can be operated on a batch or
continuous basis. The type of process will depend upon the
configuration of the metal being treated. The contact time within
the medium ranges from about 10 seconds to about 50 minutes and
normally about 1 to about 15 minutes. The inventive process can be
practiced in any suitable apparatus. Examples of suitable apparatus
comprise a conventional barrel dip apparatus.
[0021] The medium can be a fluid bath, gel, spray, among other
methods for contacting the substrate with the medium. Examples of
the medium comprise a bath containing at least one oxygen
containing water soluble compound, and a thickener, among others.
The bath can comprise any suitable polar carrier such as water,
alcohol, ethers, among others. Normally, the bath comprises at
least one water-soluble compound and de-ionized water and
optionally at least one dopant (e.g. a chloride). Typically, the at
least one dopant is water soluble or dispersible within an aqueous
medium.
[0022] The medium typically has a basic pH. Normally, the pH will
range from greater than about 9 to about 13 and typically, about 10
to about 11. The pH of the medium can be monitored and maintained
by using conventional detection methods. Alternatively, the medium
can have an acidic pH. The selected pH will depend upon whether the
metal surface is at least partially dissolved (or solubilized).
That is, the inventive process employs a medium that is at least
somewhat corrosive to the metal surface in order to enhance an
interaction between the medium and the metal.
[0023] The medium is normally aqueous and can comprise at least one
water soluble or dispersible compound in an amount from greater
than about 0 to about 40 wt. %, usually, about 3 to 15 wt. % and
typically about 10 wt. %. The medium is also normally substantially
free of heavy metals, chromates and/or phosphates.
[0024] The temperature of the medium can be controlled to optimize
the interaction between the medium and a metal surface. Normally,
the temperature will range from about 50 C to at least about 100 C
and typically about 80 to 100 C. This temperature can be maintained
by using conventional heaters and related control systems.
[0025] The chemical and/or physical properties of the medium can be
affected by exposing the medium to a source of electrical or
magnetic energy. For example, the bath can be exposed to a source
of energy such as the electrical current described in copending and
commonly assigned U.S. Ser. No. 09/824,641; hereby incorporated by
reference. Such exposure can improve the interaction between the
medium and the metal surface, partially polymerize the medium,
modify the metal to oxygen ratio, concentrate the medium, among
other desirable properties.
[0026] The medium can be modified by adding water/polar carrier
dispersible or soluble polymers. If utilized, the amount of polymer
or water dispersible materials normally ranges from about 0 wt. %
to about 10 wt. %. Examples of polymers or water dispersible
materials that can be employed in the medium comprise at least one
member selected from the group of acrylic copolymers (supplied
commercially as Carbopol.RTM.), hydroxyethyl cellulose, clays such
as bentonite, fumed silica, among others.
[0027] In an aspect of the invention, the medium is modified to
include at least one dopant material. The dopants can be useful for
building additional thickness of the deposited layer. The amount of
dopant can vary depending upon the properties of the dopant and
desired results. Typically, the amount of dopant will range from
about 0.001 wt. % to about 5 wt. % (or greater so long as the
deposition rate is not adversely affected). Examples of suitable
dopants comprise at least one member selected from the group of
water soluble salts, oxides and precursors of tungsten, molybdenum,
titanium (titatantes), zircon, vanadium, phosphorus, aluminum
(aluminates), iron (e.g., iron chloride), boron (borates), bismuth,
gallium, tellurium, germanium, antimony, niobium (also known as
columbium), magnesium and manganese, sulfur, zirconium (zirconates)
mixtures thereof, among others, and usually, salts and oxides of
aluminum and iron, and other water soluble or dispersible
monovalent species. The dopant can comprise at least one of
molybdenic acid, fluorotitanic acid and salts thereof such as
titanium hydrofluoride, ammonium fluorotitanate, ammonium
fluorosilicate and sodium fluorotitanate; fluorozirconic acid and
salts thereof such as H.sub.2ZrF.sub.6, (NH.sub.4).sub.2ZrF.sub.6
and Na.sub.2ZrF.sub.6; among others. Alternatively, dopants can
comprise at least one substantially water insoluble material such
as electropheritic transportable polymers, PTFE, boron nitride,
silica, silicon carbide, silicon nitride, aluminum nitride,
titanium carbide, diamond, titanium diboride, tungsten carbide,
metal oxides such as cerium oxide, powdered metals and metallic
precursors such as zinc, among others.
[0028] The aforementioned dopants can be employed for enhancing
mineral layer formation rate, modifying the chemistry and/or
physical properties of the resultant layer, as a diluent for the
medium, among others. Examples of such dopants are iron salts
(ferrous chloride, sulfate, nitrate), aluminum fluoride,
fluorosilicates (e.g., K2SiF6), fluoroaluminates (e.g., potassium
fluoroaluminate such as K2AlF5-H2O), mixtures thereof, among other
sources of metals and halogens. The dopant materials can be
introduced to the metal surface in pretreatment steps, in post
treatment steps (e.g., rinse), and/or by alternating exposing the
metal surface to solutions of dopants and solutions of the medium.
The presence of dopants in the medium can be employed to form
tailored surfaces upon the metal, e.g., an aqueous solution
containing aluminate can be employed to form a layer comprising
oxides of boron and aluminum. That is, at least one dopant (e.g.,
zinc) can be co-deposited along with at least one water soluble
species (e.g., a mineral) upon the substrate.
[0029] The medium can also be modified by adding at least one
diluent. Examples of suitable diluent comprise at least one member
selected from the group of sodium sulphate, surfactants,
de-foamers, colorants/dyes, conductivity modifiers, among others.
The diluent (e.g., sodium sulfate) can be employed for reducing the
affects of contaminants entering the medium, reducing bath foam,
among others. When the diluent is employed as a defoamer, the
amount normally comprises less than about 5 wt. % of the medium,
e.g., about 1 to about 2 wt. %.
[0030] In some cases the effectiveness of the deposition can be
improved by introducing an electrical current into the medium. The
metal surface can be employed as either the anode or cathode (e.g.,
as described in aforementioned U.S. patent application Ser. No.
09/814,641). Typically, when the medium is acidic the metal surface
comprises the anode whereas for basic mediums the metal surface
comprises the cathode. The current and voltage can be varied but
normally the conditions are such that hydrogen evolves from the
cathode and oxygen from the anode.
[0031] Contact with the inventive medium can be preceded by and/or
followed with conventional pre-treatments and/or post-treatments
known in this art such as cleaning or rinsing, e.g.,
immersion/spray within the treatment, sonic cleaning, double
counter-current cascading flow; alkali or acid treatments, among
other treatments. By employing a suitable post- or pre-treatment
the solubility, corrosion resistance (e.g., reduced white rust
formation when treating zinc containing surfaces), sealer and/or
topcoat adhesion, among other properties of surface of the
substrate formed by the inventive method can be improved. If
desired, the post-treated surface can be sealed, rinsed and/or
topcoated, e.g., silane, epoxy, latex, fluoropolymer, acrylic,
among other coatings.
[0032] In one aspect of the invention, a pre-treatment comprises
exposing the substrate to be treated to at least one of an acid,
oxidizer, a basic solution (e.g., zinc and sodium hydroxide) among
other compounds. The pre-treatment can be employed for removing
excess oxides or scale, equipotentialize the surface for subsequent
mineralization treatments, convert the surface into a mineral
precursor, among other benefits. Conventional methods for acid
cleaning metal surfaces are described in ASM, Vol. 5, Surface
Engineering (1994), and U.S. Pat. No. 6,096,650; hereby
incorporated by reference.
[0033] In one aspect of the invention, the metal surface is
pre-treated or cleaned electrolytically by being exposed to an
anodic environment. That is, the metal surface is exposed to the
medium wherein the metal surface is the anode and a current is
introduced into the medium. By using the metal as the anode in a DC
cell and maintaining a current of about 10 A/ft2 to about 150
A/ft2, the process can generate oxygen gas. The oxygen gas agitates
the surface of the workpiece while oxidizing the substrate's
surface. The surface can also be agitated mechanically by using
conventional vibrating equipment. If desired, the amount of oxygen
or other gas present during formation of the mineral layer can be
increased by physically introducing such gas, e.g., bubbling,
pumping, among other means for adding gases.
[0034] If desired, the inventive method can include a thermal
post-treatment. The metal surface can be removed from the silicate
medium, dried (e.g., at about 120 to about 150 C for about 2.5 to
about 10 minutes), rinsed in deionized water and then dried. The
dried surface may be processed further as desired; e.g. contacted
with a sealer, rinse or topcoat. In an aspect of the invention, the
thermal post treatment comprises heating the surface. Typically the
amount of heating is sufficient to consolidate or densify the
inventive surface without adversely affecting the physical
properties of the underlying metal substrate. Heating can occur
under atmospheric conditions, within a nitrogen containing
environment, among other gases. Alternatively, heating can occur in
a vacuum. The surface may be heated to any temperature within the
stability limits of the surface coating and the surface material.
Typically, surfaces are heated from about 75.degree. C. to about
250.degree. C., more typically from about 120.degree. C. to about
200.degree. C. If desired, the heat treated component can be rinsed
in water to remove any residual water soluble species and then
dried again (e.g., dried at a temperature and time sufficient to
remove water).
[0035] In one aspect of the invention, a post treatment comprises
exposing the substrate to a source of at least one carbonate or
precursors thereof. Examples of carbonate comprise at least one
member from the group of gaseous carbon dioxide, lithium carbonate,
lithium bicarbonate, sodium carbonate, sodium bicarbonate,
potassium carbonate, potassium bicarbonate, rubidium carbonate,
rubidium bicarbonate, rubidium acid carbonate, cesium carbonate,
ammonium carbonate, ammonium bicarbonate, ammonium carbamate and
ammonium zirconyl carbonate. Normally, the carbonate source will be
water soluble. In the case of a carbonate precursor such as carbon
dioxide, the precursor can be passed through a liquid (including
the medium) and the substrate immersed in the liquid. One specific
example of a suitable postreatment is disclosed in U.S. Pat. No.
2,462,763; hereby incorporated by reference. Another specific
example of a post treatment comprises exposing a treated surface to
a solution obtained by diluting ammonium zirconyl carbonate (1:4)
in distilled water (e.g., Bacote.RTM. 20 supplied by Magnesium
Elektron Corp). If desired, the surface treated by the inventive
process is dried and, then, post-treated with a carbonate (e.g.,
zirconyl ammonium carbonate). Further in some case, a carbonate
post treated surface can be topcoated (e.g., aqueous or water borne
topcoats).
[0036] In another aspect of the invention, the post treatment
comprises heating the surface. Typically the amount of heating is
sufficient to densify the inventive surface without adversely
affecting the physical properties of the underlying metal
substrate. Heating can occur under atmospheric conditions, within a
nitrogen containing environment, among other gases. If desired,
prior to heating the inventive surface can be contacted with a
solution containing a material that interacts with the surface at
elevated temperatures, e.g., a eutectic formed between the metal
surface and at least one of silica, alumina, B2O3, iron oxide, MgO,
among other compounds. Normally, the heating will be sufficient to
cause sintering or a desirable interaction without adversely
affecting the underlying metal.
[0037] In another aspect of the invention, the post treatment
comprises exposing the substrate to a source comprising at least
one acid source or precursors thereof. Examples of suitable acid
sources comprise at least one member chosen from the group of
phosphoric acid, hydrochloric acid, molybdic acid, silicic acid,
acetic acid, citric acid, nitric acid, hydroxyl substituted
carboxylic acid, glycolic acid, lactic acid, malic acid, tartaric
acid, ammonium hydrogen citrate, ammonium bifluoride, fluoboric
acid, fluorosilicic acid, among other acid sources effective at
improving at least one property of the treated metal surface. The
Ph of the acid post treatment may be modified by employing at least
one member selected from the group consisting of ammonium citrate
dibasic (available commercially as Citrosol.RTM. #503 and
Multiprep.RTM.), fluoride salts such as ammonium bifluoride,
fluoboric acid, fluorosilicic acid, among others. The acid post
treatment can serve to activate the surface thereby improving the
effectiveness of rinses, sealers and/or topcoatings (e.g., surface
activation prior to contacting with a sealer can improve cohesion
between the surface and the sealer thereby improving the corrosion
resistance of the treated substrate). Normally, the acid source
will be water soluble and employed in amounts of up to about 15 wt.
% and typically, about 1 to about 5 wt. % and have a Ph of less
than about 5.5.
[0038] In another aspect of the invention, the post treatment
comprises contacting a surface treated by the inventive process
with a rinse. By "rinse" it is meant that an article or a treated
surface is sprayed, dipped, immersed or other wise exposed to the
rinse in order to affect the properties of the treated surface. For
example, a surface treated by the inventive process is immersed in
a bath comprising at least one rinse. In some cases, the rinse can
interact or react with at least a portion of the treated surface.
Further the rinsed surfaced can be modified by multiple rinses,
heating, topcoating, adding dyes, lubricants and waxes, among other
processes. Examples of suitable compounds for use in rinses
comprise at least one member selected from the group of titanates,
titanium chloride, tin chloride, zirconates, zirconium acetate,
zirconium oxychloride, fluorides such as calcium fluoride, tin
fluoride, titanium fluoride, zirconium fluoride; coppurous
compounds, ammonium fluorosilicate, metal treated silicas (e.g.,
Ludox.RTM.), nitrates such as aluminum nitrate; sulphates such as
magnesium sulphate, sodium sulphate, zinc sulphate, and copper
sulphate; lithium compounds such as lithium acetate, lithium
bicarbonate, lithium citrate, lithium metaborate, lithium vanadate,
lithium tungstate, among others. The rinse can further comprise at
least one organic compound such as vinyl acrylics,
fluorosurfactancts, polyethylene wax, among others. Examples of
commercially available sealers, rinses and topcoats comprise at
least one member selected from the group of Aqualac.RTM. (urethane
containing aqueous solution), W86.RTM., W87.RTM., B37.RTM.,
T01.RTM., E10.RTM., B17, B18 among others (a heat cured coating
supplied by the Magni.RTM. Group), JS2030S (sodium silicate
containing rinse supplied by MacDermid Incorporated), JS20401 (a
molybdenum containing rinse also supplied by MacDermid
Incorporated), EnSeal.RTM. C-23 (an acrylic based coating supplied
by Enthone), EnSeal.RTM. C-26, Enthone.RTM. C-40 (a pigmented
coating supplied Enthone), Microseal.RTM., Paraclene.RTM. 99 (a
chromate containing rinse), EcoTri.RTM. (a silicate/polymer rinse),
MCI Plus OS (supplied by Metal Coatings International), silanes
(e.g., Dow Corning Z-6040, Gelest SIA 0610.0, among others),
ammonium zirconyl carbonate (e.g., Bacote 20), urethanes (e.g.,
Agate L18), among others. One specific rinse comprises water, water
dispersible urethane, and at least one silicate, e.g., refer to
commonly assigned U.S. Pat. No. 5,871,668; hereby incorporated by
reference. While the rinse can be employed neat, normally the rinse
will be dissolved, diluted or dispersed within another medium such
as water, organic solvents, among others. While the amount of rinse
employed depends upon the desired results, normally the rinse
comprises about 0.1 wt % to about 50 wt. % of the rinse medium. The
rinse can be employed as multiple applications and, if desired,
heated. Moreover, the aforementioned rinses can be modified by
incorporating at least one dopant, e.g. the aforementioned dopants.
The dopant can employed for interacting or reacting with the
treated surface. If desired, the dopant can be dispersed in a
suitable medium such as water and employed as a rinse.
[0039] The inventive process can create a flexible surface that can
survive secondary processes, e.g., metal deformation for riveting,
sweging, crimping, among other processes, and continue to provide
corrosion protection. Such is in contrast to typical corrosion
inhibitors such as chromates that tend to crack when the underlying
surface is shaped. If desired, the surface formed by the inventive
process can be topcoated (e.g, with a heat cured epoxy), prior to
secondary processing. Articles treated in accordance with the
inventive process, topcoated and exposed to a secondary process
retain their desirable corrosion resistance, coating adhesion,
component functionality, among properties.
[0040] The inventive process can provide a surface (e.g., mineral
coating) that can enhance the surface characteristics of the metal
or conductive surface such as resistance to corrosion, protect
carbon (fibers for example) from oxidation, stress crack corrosion
(e.g., stainless steel), hardness, thermal resistance, improve
bonding strength in composite materials, provide dielectric layers,
improve corrosion resistance of printed circuit/wiring boards and
decorative metal finishes, and reduce the conductivity of
conductive polymer surfaces including application in sandwich type
materials.
[0041] The mineral coating can also affect the electrical and
magnetic properties of the surface. That is, the mineral coating
can impart electrical resistance or insulative properties to the
treated surface. By having an electrically non-conductive surface,
articles having the inventive layer can reduce, if not eliminate,
electro-galvanic corrosion in fixtures wherein current flow is
associated with corrosion, e.g., bridges, pipelines, among other
articles.
[0042] Depending upon the intended usage of the workpiece treated
by the inventive method, the workpiece can be coated with a
secondary coating or layer. Alternatively, the treated workpiece
can be rinsed (as described above) and then coated with a secondary
coating or layer. Examples of such secondary coatings or layers
comprise one or more members of acrylic coatings (e.g.,
IRILAC.RTM.), e-coats, silanes including those having amine,
acrylic and aliphatic epoxy functional groups, latex, urethane,
epoxies, silicones, alkyds, phenoxy resins (powdered and liquid
forms), radiation curable coatings (e.g., UV curable coatings),
lacquer, shellac, linseed oil, among others. Secondary coatings can
be solvent or water borne systems. The secondary coatings can be
applied by using any suitable conventional method such as
immersing, dip-spin, spraying, among other methods. The secondary
coatings can be cured by any suitable method such as UV exposure,
heating, allowed to dry under ambient conditions, among other
methods. An example of UV curable coating is described in U.S. Pat.
Nos. 6,174,932 and 6,057,382; hereby incorporated by reference.
Normally, the surface formed by the inventive process will be
rinsed, e.g., with at least one of deionized water, silane or a
carbonate, prior to applying a topcoat. The secondary coatings can
be employed for imparting a wide range of properties such as
improved corrosion resistance to the underlying mineral layer,
reduce torque tension, a temporary coating for shipping the treated
workpiece, decorative finish, static dissipation, electronic
shielding, hydrogen and/or atomic oxygen barrier, among other
utilities. The mineral coated metal, with or without the secondary
coating, can be used as a finished product or a component to
fabricate another article.
[0043] The thickness of the rinse, sealer and/or topcoat can range
from about 0.00001 inch to about 0.025 inch. The selected thickness
varies depending upon the end use of the coated article. In the
case of articles having close dimensional tolerances, e.g.,
threaded fasteners, normally the thickness is less than about
0.00005 inch.
[0044] In another aspect, the treated metal surface is contacted
with a secondary coating. Examples of such secondary coatings and
methods that can be complimentary to the instant invention are
described in U.S. Pat. Nos. 5,759,629; 5,750,197; 5,539,031;
5,498,481; 5,478,655; 5,455,080; and 5,433,976. The disclosure of
each of these U.S. patents is hereby incorporated by reference. For
example, improved corrosion resistance of a metal substrate can be
achieved by using a secondary coating comprising at least one
suitable silane (e.g., in the medium, rinse, sealer and/or topcoat)
in combination with a mineralized surface. Examples of suitable
silanes comprise at least one members selected from the group
consisting of tetra-ortho-ethyl-silicate (TEOS),
bis-1,2-(triethoxysilyl) ethane (BSTE), vinyl silane or aminopropyl
silane, epoxy silanes, vinyltriactosilane, alkoxysilanes, among
other organo functional silanes. The silane can bond with the
mineralized surface and then the silane can cure thereby providing
a protective top coat, or a surface for receiving an outer coating
or layer. In some cases, it is desirable to sequentially apply the
silanes. For example, a steel substrate, e.g., a fastener, can be
treated by the inventive process to form a mineral layer, allowed
to dry, rinsed in deionized water, coated with a 5% BSTE solution,
coated again with a 5% vinyl silane solution, and powder coated
with a thermoset epoxy paint (Corvel 10-1002 by Morton) at a
thickness of 2 mils.
[0045] The inventive process forms a surface that may have improved
adhesion to outer coatings or layers, e.g., secondary coatings.
Examples of suitable outer coatings comprise at least one member
selected from the group consisting of acrylics, epoxies, e-coats,
latex, urethanes, silanes (e.g., TEOS, MEOS, among others),
fluoropolymers, alkyds, silicones, polyesters, oils, gels, grease,
among others. An example of a suitable epoxy comprises a coating
supplied by The Magni.RTM. Group as B17 or B18 top coats, e.g, a
galvanized article that has been treated in accordance with the
inventive method and contacted with at least one silane and/or
ammonium zirconium carbonate and top coated with a heat cured epoxy
(Magni.RTM. B18) thereby providing a chromate free corrosion
resistant article. By selecting appropriate rinses, secondary and
outer coatings for application upon the mineral, a corrosion
resistant article can be obtained without chromating or
phosphating. Such a selection can also reduce usage of zinc to
galvanize iron containing surfaces, e.g., a steel surface is
mineralized, coated with a silane containing coating and with an
outer coating comprising an epoxy.
[0046] Without wishing to be bound by any theory or explanation, it
is believed that the inventive process forms a surface that can
release or provide water or related moieties. These moieties can
participate in a hydrolysis or condensation reaction that can occur
when an overlying rinse, seal or topcoating cures. Such
participation improves the cohesive bond strength between the
surface and overlying cured coating.
[0047] The surface formed by the inventive process can also be
employed as an intermediate or tie-layer for glass coatings, glass
to metal seals, hermetic sealing, among other applications wherein
it is desirable to have a joint or bond between a metallic
substrate and a glass layer or article. The inventive surface can
serve to receive molten fluids (e.g., zinc, aluminum, steel,
borosilicate, aluminosilicate, phosphate, among other glasses),
while protecting the underlying metallic substrate and forming a
seal.
[0048] The inventive process can provide a surface that improves
adhesion between a treated substrate and an adhesive. Examples of
adhesives comprise at least one member selected from the group
consisting of hot melts such as at least one member selected from
the group of polyamides, polyimides, butyls, acrylic modified
compounds, maleic anhydride modified ethyl vinyl acetates, maleic
anhydride modified polyethylenes, hydroxyl terminated ethyl vinyl
acetates, carboxyl terminated ethyl vinyl acetates, acid terpolymer
ethyl vinyl acetates, ethylene acrylates, single phase systems such
as dicyanimide cure epoxies, polyamide cure systems, lewis acid
cure systems, polysulfides, moisture cure urethanes, two phase
systems such as epoxies, activated acrylates polysulfides,
polyurethanes, among others. Two metal substrates having surfaces
treated in accordance with the inventive process can be joined
together by using an adhesive. Alternatively one substrate having
the inventive surface can be adhered to another material, e.g.,
joining treated metals to plastics, ceramics, glass, among other
surfaces. In one specific aspect, the substrate comprises an
automotive hem joint wherein the adhesive is located within the
hem.
[0049] The improved cohesive and adhesive characteristics between a
surface formed by the inventive process and polymeric materials can
permit forming acoustical and mechanical dampeners, e.g.,
constraint layer dampers such as described in U.S. Pat. No.
5,678,826 hereby incorporated by reference, motor mounts,
bridge/building bearings, HVAC silencers, highway/airport sound
barriers, among other articles. The ability to improve the bond
between vistoelastomeric materials sandwiched between metal panels
in dampers reduces sound transmission, improves formability of such
panels, reduces process variability, among other improvements. The
metal panels can comprise any suitable metal such as 304 steel,
stainless steel, aluminum, cold rolled steel, zinc alloys, hot
dipped zinc or electrogalvanized, among other materials. Examples
of polymers that can be bonded to the inventive surface and in turn
to an underlying metal substrate comprise any suitable material
such as neoprene, EPDM, SBR, EPDM, among others. The inventive
surface can also provide elastomer to metal bonds described in U.S.
Pat. No. 5,942,333; hereby incorporated by reference.
[0050] The inventive process can employ dopants, rinses, sealers
and/or topcoats for providing a surface having improved thermal and
wear resistance. Such surfaces can be employed in gears (e.g.,
transmission), powdered metal articles, exhaust systems including
manifolds, metal flooring/grates, heating elements, among other
applications wherein it is desirable to improve the resistance of
metallic surfaces.
[0051] In another aspect of the invention, the inventive process
can be used to produce a surface that reduces, if not eliminates,
molten metal adhesion (e.g., by reducing intermetallic formation).
Without wishing to be bound by any theory or explanation, it is
believed that the inventive process provides an ablative and/or a
reactive film or coating upon an article or a member that can
interact or react with molten metal thereby reducing adhesion to
the bulk article. For example, the inventive process can provide an
inorganic iron or a zinc containing film or layer upon a substrate
in order to shield or isolate the substrate from molten metal
contact (e.g., molten aluminum or magnesium). The effectiveness of
the film or layer can be improved by applying an additional coating
comprising silica (e.g., to function as an ablative when exposed to
molten metal). The ability to prevent molten metal adhesion is
desirable when die casting aluminum or magnesium over zinc cores,
die casting aluminum for electronic components, among other uses.
The molten metal adhesion can be reduced further by applying one of
the aforementioned topcoatings, e.g. Magni.RTM. B18, acrylics,
polyesters, among others. The topcoatings can be modified (e.g., to
be more heat resistant) by adding a heat resistant material such as
colloidal silica (e.g., Ludox.RTM. which can also be added to the
medium and rinse).
[0052] While the above description places particular emphasis upon
forming a mineral containing layer upon a metal surface, the
inventive process can be combined with or replace conventional
metal pre or post treatment and/or finishing practices.
Conventional post coating baking methods can be employed for
modifying the physical characteristics of the mineral layer, remove
water and/or hydrogen, among other modifications. The inventive
mineral layer can be employed to protect a metal finish from
corrosion thereby replacing conventional phosphating process, e.g.,
in the case of automotive metal finishing the inventive process
could be utilized instead of phosphates and chromates and prior to
coating application e.g., E-Coat. The inventive process can be
employed for imparting enhanced corrosion resistance to electronic
components. The inventive process can also be employed in a
virtually unlimited array of end-uses such as in conventional
plating operations as well as being adaptable to field service. For
example, the inventive mineral containing coating can be employed
to fabricate corrosion resistant metal products that conventionally
utilize zinc as a protective coating, e.g., automotive bodies and
components, grain silos, bridges, among many other end-uses.
Moreover, depending upon the dopants and concentration thereof
present in the mineral deposition solution, the inventive process
can produce microelectronic films, e.g., on metal or conductive
surfaces in order to impart enhanced electrical/magnetic (e.g., EMI
shielding, reduced electrical connector fretting, reduce corrosion
caused by dissimilar metal contact, among others), and corrosion
resistance, or to resist ultraviolet light and monotomic oxygen
containing environments such as outer space.
[0053] The following Examples are provided to illustrate certain
aspects of the invention and it is understood that such an Example
does not limit the scope of the invention.
EXAMPLES
[0054] The examples illustrate electroless deposition that was
conducted in NaOH solution along with various oxygen containing
water soluble compounds. All deposition studies were done at a Ph
of 11 and temperature of 75.degree. C. The mineralization process
was done on bare steel, Sn plated steel, hot dip galvanized steel
and electro-galvanized steel using the following solutions:
[0055] Deposition in NaOH solution+1 g/L sodium stannate
trihydrate
[0056] Deposition in NaOH+1 g/L sodium molybdate dihydrate
[0057] Deposition in NaOH solution+1 g/L ammonium metavanadate
[0058] Deposition in NaOH solution+1 g/L cerium nitrate
hexahydrate
[0059] Subsequent to electroless deposition, the panels were
removed from the bath and washed with deionized (DI) water
immediately.
[0060] Next, the corrosion characteristics of the panel were
studied in 0.5 M Na.sub.2SO.sub.4 solution at Ph 4. A
representative panel area of 1 cm.sup.2 was chosen for testing. A
three-electrode setup was used to study the corrosion behavior of
the mineralized samples. The electrolyte used in this study is 0.5
M sodium sulfate, Ph=4. Ti coated with Pd was used as the counter
electrode. Hg/Hg.sub.2SO.sub.4 was used as the reference electrode.
All potentials in this study are referred with respect to the
Hg/Hg.sub.2SO.sub.4 electrode. Corrosion studies were done using
Scribner Associates Corrware Software with EG&G Princeton
applied Model 273 potentiostat/galvanostat and a Solartron 1255
frequency analyzer. The electrode was left on open circuit till
it's potential stabilized. After the potential stabilized,
non-destructive evaluation of the surface was done using linear
polarization and impedance analysis. During linear polarization,
the potential was varied 10 Mv above and below the open circuit
potential of the mineralized sample at a scan rate of 0.1667 Mv/s.
The impedance data generally covered a frequency range of 5 mHz to
10 kHz. A sinusoidal ac voltage signal varying by .+-.10 Mv was
applied. The electrode was stable during the experiments and its
open circuit potential changed less than 1 Mv.
[0061] The results of the corrosion studies are detailed below in
Tables 1-3.
1TABLE 1 Corrosion Resistance for Samples Immersed in NaOH + Sodium
Stannate Solution Specimen Rp - Avg Substrate # Rp
(.OMEGA.-cm.sup.2) (.OMEGA.-cm.sup.2) Fe--Sn 1 365106 316867 356816
542530 395329.8 Steel (Fe) 2 4194 5136 3718 5061 4527.25 Steel (Fe)
3 4807 8061 13443 754 6766.25 Galvalume 4 1111 1516 1374 854
1213.75 Galvalume 5 1596 1886 1395 678 1388.75 Fe--Zn 6 1009 330
852 935 781.5 Fe--Zn 7 1601 750 902 355 902
[0062]
2TABLE 2 Corrosion Resistance for Samples Immersed in NaOH + Sodium
Molybdate Solution Specimen Rp - Avg Substrate # Rp
(.OMEGA.-cm.sup.2) (.OMEGA.-cm.sup.2) Fe--Sn 1 139047 252466 378666
234211 251098 2 20096 656490 331291 3121 252750 Steel (Fe) 3 841
1186 994 817 959.5 Steel (Fe) 4 1478 794 1120 885 1069.25 Galvalume
5 2567 1957 1496 1846 1966.5 Galvalume 6 2120 2013 2173 1553
1964.75 Fe--Zn 7 870 816 779 798 815.75 Fe--Zn 8 959 1181 834 1150
1031
[0063]
3TABLE 3 Corrosion Resistance for Samples Immersed in NaOH + Cerium
Nitrate Specimen Rp - Avg Substrate # Rp (.OMEGA.-cm.sup.2)
(.OMEGA.-cm.sup.2) Fe--Sn 1 50861 170332 46192 20867 72063 2 36760
76518 140604 53238 76780 Steel (Fe) 3 747 495 848 947 759.25 Steel
(Fe) 4 544 1323 629 1269 941.25 Galvalume 5 838 364 1329 947 869.5
Galvalume 6 1363 1214 1354 879 1202.5 Fe--Zn 7 1065 1074 1344 947
1107.5 Fe--Zn 8 723 682 846 663 728.5
* * * * *