# US 10,767,265 B2 · Inorganic phosphate corrosion resistant coatings

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- Number: US 10,767,265 B2
- Document ID: US10767265B2
- Status: Granted
- Kind: B2
- Application number: 16/262,567
- Filed: 2019-01-30
- Published: 2019-06-20
- Granted: 2020-09-08
- Earliest claimed: 2013-08-12
- Assignees: Latitude 18, Inc.
- Applicants: Latitude 18, Inc.
- Inventors: Sameerkumar Vasantlal Patel; Benjamin Chaloner-Gill; Anthony V. Collins
- Web page: https://patentgrep.com/patent/US10767265B2

## CPC

- C23C 22/22: containing alkaline earth metal cations
- C04B 28/34: containing cold phosphate binders
- C04B 35/447: based on phosphates {, e.g. hydroxyapatite}
- C09D 5/084: {Inorganic compounds}
- C23C 22/68: using aqueous solutions with pH between 6 and 8
- C04B 2111/00525: {for metallic surfaces}
- 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 (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

This disclosure relates to compositions for protecting a metallic surface susceptible to corrosion, the composition comprising a first component comprising an aqueous mixture of an acid-phosphate of chemical formula Am(H2PO4)m.nH2O, where A is hydrogen ion, ammonium cation, metal cation, or mixtures thereof where m=1-3, and n=0-6; the first component solution adjusted to a pH of about 2 to about 5, the first component having a particle size distribution between 0.04 to 60 micron; and a second component, configured for combination and at least partial reaction with the first component to provide a phosphate ceramic, the second component comprising an aqueous solution or suspension of an alkaline oxide or alkaline hydroxide represented by B2mOm, B(OH)2m, or mixtures thereof, where B is an element of valency 2m (m=1, 1.5, or 2) the second component solution adjusted to a pH of between 9-14.

## Claims

### Claim 1

A phosphate ceramic precursor composition comprising:
an aqueous mixture of suspended, dispersed, or slurried particles of an acid-phosphate of chemical formula Am(H2PO4)m.nH2O, where A is hydrogen ion, ammonium cation, metal cation, or mixtures thereof; where m=1-3, and n=0-6, adjusted to a pH of about 2 to about 5, wherein the particles of the acid-phosphate have an average particle size of less than 30 microns, and about 90 percent of the particles of the acid-phosphate have a particle size distribution of less than 30 microns; and
an aqueous mixture of suspended, dispersed, or slurried particles of an alkaline oxide or alkaline hydroxide represented by B2mOm, B(OH)2m, or mixtures thereof, where B is an element of valency 2m, where m=1, 1.5, or 2 adjusted to a pH of between 9-14 and configured for combination and at least partial reaction with the acid-phosphate to provide a phosphate ceramic; and
wherein the suspended, dispersed, or slurried particles of the acid-phosphate are present in an amount of at least about 60 wt % to about 80 wt % in the aqueous mixture thereof.

### Claim 2 (depends on 1)

The phosphate ceramic precursor composition of claim 1, wherein the aqueous mixture of suspended, dispersed, or slurried particles of acid-phosphate comprises mono potassium phosphate or mono calcium phosphate, and optionally about 2 to about 10 wt % phosphoric acid of the aqueous mixture thereof, and wherein the alkaline oxide or alkaline hydroxide is magnesium oxide, calcium oxide, magnesium hydroxide or calcium hydroxide.

### Claim 3 (depends on 2)

The phosphate ceramic precursor composition of claim 2, further comprising at least one selected from the group of a mineral silicate, wollastonite, talc, amorphous magnesium silicate, amorphous calcium silicate, diatomaceous earth, silicon dioxide and amorphous silicon dioxide, and a rheology modifier/suspending agent, wherein the rheology modifier/suspending agent is at least one selected from the group of guar gum, diutan gum, welan gum, and xanthan gum present in an amount of 0.15-15 weight percent of either aqueous mixture of acid-phosphate or alkaline oxide or alkaline hydroxide.

### Claim 4

A method of providing corrosion protection to a metal surface, the method comprising:
contacting a metal surface with a first component and a second component, in any order or in combination;
wherein the first component comprises an aqueous mixture of suspended, dispersed, or slurried particles of an acid-phosphate of chemical formula Am(H2PO4)m.nH2O, where A is hydrogen ion, ammonium cation, metal cation, or mixtures thereof; where m=1-3, and n=0-6 adjusted to a pH of about 2 to about 5, wherein the particles of the acid phosphate have an average particle size of less than 30 microns, and about 90 percent of the particles of the acid phosphate have a particle size distribution of less than 30 microns; and
wherein the second component comprises an aqueous mixture of suspended, dispersed, or slurried particles of an alkaline oxide or alkaline hydroxide represented by B2mOm, B(OH)2m, or mixtures thereof, where B is an element of valency 2m where m=1, 1.5, or 2 adjusted to a pH of between 9-14 and
configured for combination and at least partial reaction with the first component to provide a phosphate ceramic; and
wherein the suspended, dispersed, or slurried particles of the acid-phosphate are present in an amount of at least about 60 wt % to about 80 wt % in the aqueous mixture thereof;
providing corrosion protection to the metal surface.

### Claim 5 (depends on 4)

The method of claim 4, wherein the first component comprises a dihydrogen phosphate salt of formula Mm(H2PO4)m, its hydrates, or mixtures thereof; where M is sodium, potassium, magnesium, calcium, aluminum, or mixtures thereof, and m is 1-3.

### Claim 6 (depends on 4)

The method of claim 4, wherein the first component comprises water and mono potassium phosphate or mono calcium phosphate, and optionally, about 2 to about 10 wt % phosphoric acid, and wherein the second component is water and magnesium oxide, calcium oxide, magnesium hydroxide or calcium hydroxide.

### Claim 7 (depends on 4)

The method of claim 4, wherein the second component is present in an amount of at least about 60 wt % to about 80 wt % in the aqueous mixture thereof.

### Claim 8 (depends on 4)

A product coated by the method of claim 4.