Coated metal formed article and method for producing coated metal formed material

A method for forming a coated metal formed article, comprising the steps (1) to (4)

• (1) preparing step for a metal formed article;
• (2) forming step for a zinc-containing porous layer on the metal formed article by using a thermal-spraying device;
• (3) forming step for a phenol-modified silicon compound layer on the zinc-containing layer;
• (4) forming step for a fluorine resincontaining layer on the phenol-modified silicon compound layer, said fluorine resin-containing layer including a fluorine resin and at least one organic resin selected from a polyester resin, a polyacryl resin, a polyolefin resin, a polyurethane resin, and a polycarbonate resin, wherein an amount of the fluorine resin added is in a range of 1 to 200 parts by weight with respect to 100 parts by weight of the organic resin, and
• wherein when a thickness of the phenol-modified silicon compound layer is t2 (μm) and a thickness of the fluorine resin-containing layer is t1 (μm), a ratio of t1 to t2 is in a range of 0.05 to 50 so that dimensional accuracy and mechanical properties are increased.

A coated metal formed article, consisting essentially of:

• a metal formed article,
• a zinc-containing porous coating layer laminated on a surface of the metal formed article,
• a phenolmodified silicon compound layer laminated on the zinc-containing porous coating layer, and
• a fluorine resin-containing layer laminated on the phenol-modified silicon compound layer, wherein the fluorine resin-containing layer contains a fluorine resin and at least one organic resin selected from a polyester resin, a polyacryl resin, a polyolefin resin, a polyurethane resin, and a polycarbonate resin, wherein an amount of the fluorine resin added is in a range of 10 to 40 parts by weight with respect to 100 parts by weight of the organic resin, and
• wherein when a thickness of the phenolmodified silicon compound layer is t2 (μm) and a thickness of the fluorine resin-containing layer is t1 (μm), a ratio of t1 to t2 is in a range of 0.05 to 50 50 that dimensional accuracy and mechanical properties are increased.