# US 2014/0190836 A1 · Anti-corrosion electrocoat

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- Number: US 2014/0190836 A1
- Document ID: US20140190836A1
- Status: Published application
- Kind: A1
- Application number: 14/119,584
- Filed: 2012-05-23
- Published: 2014-07-10
- Earliest claimed: 2011-05-23
- Assignees: Axalta Coating Systems IP Co., LLC
- Inventors: Taddesse Gebregiorgis
- Web page: https://patentgrep.com/patent/US20140190836A1

## CPC

- C09D 7/61: inorganic
- C09D 5/24: Electrically-conducting paints {(conductive materials H01B1/00)}
- C09D 5/443: {Polyepoxides}
- C25D 9/10: on iron or steel
- C25D 13/22: Servicing or operating {apparatus or multistep processes}
- C25D 15/00: Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires
- 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)
- C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR

## Abstract

The present disclosure relates to the application of anti-corrosion coatings for a ferrous substrate. The first coating applied to the ferrous substrate is an electrocoat composition comprising electrically conductive pigments. A dried a cured coating layer of the first electrocoat composition provides the basis for a second electrocoat composition.

## Claims

### Claim 1

A process for the coating of a ferrous substrate comprising the steps of:
1) providing a first bath comprising a conductive pigment-containing electrocoat composition;
2) placing the ferrous substrate at least partially into the first bath;
3) passing an electric current through the first bath and the ferrous substrate to deposit a layer of the conductive pigment-containing electrocoat composition onto at least a portion of the substrate;
4) removing the ferrous substrate from the first bath;
5) rinsing the coated substrate with water;
6) heating the ferrous substrate to cure the applied layer of conductive pigment-containing electrocoat composition;
7) providing a second bath comprising a second electrocoat composition;
8) placing the ferrous substrate at least partially into the second bath;
9) passing an electric current through the second bath and the ferrous substrate to deposit a layer of the second electrocoat composition onto at least a portion of the layer of conductive pigment-containing electrocoat composition;
10) removing the coated substrate from the second bath;
11) rinsing the coated substrate with water; and
12) heating the substrate to cure the applied layer or layers of electrocoat composition,
wherein the conductive pigment-containing electrocoat composition comprises:
A) a pigment, consisting of conductive pigment;
B) an epoxy resin; and
wherein the conductive pigment-containing electrocoat composition has a pigment to binder ratio in the range of from 0.1:1 to 1:1.

### Claim 2 (depends on 1)

The process of claim 1, wherein the conductive pigment is selected from the group consisting of aluminum pigment, conductive carbon black, graphene and a combination thereof.

### Claim 3 (depends on 1)

The process of claim 1 wherein the ferrous substrate is a cold rolled steel substrate that is free from any anti-corrosion coatings or free from any anti-corrosion treatments.

### Claim 4 (depends on 1)

The process of claim 1 wherein the heating steps 6) and 12) are performed at a temperature in the range of from about 140° C. to about 240° C. for about 5 minutes to about 60 minutes.

### Claim 5 (depends on 2)

The process of claim 2, wherein the conductive carbon black has an average particle size in the range of from about 10 nanometers to about 200 nanometers.

### Claim 6 (depends on 1)

The process of claim 1 wherein the conductive pigments are dispersed using an alkylene oxide extended styrenated phenol.