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US 8,802,190 B2Granted
Weldable corrosion resistant coating for steel and method of manufacture
AssigneeHonda Motor Co., Ltd.
InventorAlan Seid
Life of this patent
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Abstract
The disclosure is directed the formulation and application of an anti-corrosion coating system for use on an associated metallic substrate, the coating composition including at least a sacrificial binder and particles of at least one metallic compound comprising a metal which is anodic relative to the metallic substrate. The associated method includes the steps of applying the coating system to the metallic substrate to form an initial coating, heating this initial coating to remove the sacrificial binder and continued heating under controlled atmospheric conditions sufficient to reduce the metallic compound(s) to elemental metal and form a corrosion suppressing alloy coating on the metallic substrate.
Claims20
A method of forming a protective coating on a metallic substrate consisting of:
- depositing a first coating composition on a surface of the substrate, the first coating composition comprising first reducible metallic particles selected from the group consisting of aluminum-containing compounds, zinc-containing compounds, or a mixture thereof, second reducible metallic particles including iron-containing compounds thereof, and a polymeric binder;
- depositing a second coating composition on a surface of the first coating composition, the second coating composition comprising first reducible metallic particles selected from the group consisting of aluminum-containing compounds, zinc-containing compounds, or a mixture thereof, second reducible metallic particles including iron-containing compounds, and a polymeric binder;
- treating the coating compositions under conditions sufficient to remove substantially all of the polymeric binder from the first and second coating compositions to form a residual layer comprising the first and second metallic particles of the first and second coating compositions;
- treating the residual layer under conditions sufficient to reduce the first and second metallic particles of the first and second coating compositions and form a reduced layer of first metal particles and second metal particles of the first and second coating compositions;
- and
- treating the reduced layer of first and second metal particles of the first and second coating compositions under conditions sufficient to form an alloy layer having a thickness on the substrate surface.
3 more elements
A method of forming a protective coating on a metallic substrate comprising:
- depositing a first coating composition on a surface of the substrate, the first coating composition consisting of first metallic particles and a polymeric binder and a first thickness;
- depositing a second coating composition on a surface of the first coating composition, the second coating composition comprising second metallic particles and a polymeric binder, the first and second coating compositions cooperating to form an initial protective coating;
- treating the initial protective coating composition under conditions sufficient to remove substantially all of the polymeric binder to form a residual layer comprising a first sublayer comprising the first metallic particles and a second sublayer comprising the second metallic particles;
- treating the residual layer under conditions sufficient to reduce the first and second metallic particles and form a reduced layer comprising a first reduced sublayer comprising first metal particles and a second reduced sublayer comprising second metal particles;
- and
- treating the reduced layer under conditions sufficient to cause the first and second reduced sublayers to form an alloy layer on the substrate surface.
3 more elements
A method of forming a protective coating on a steel substrate comprising:
- depositing a first coating composition on a surface of the steel substrate, the first coating composition consisting of first reducible metallic particles selected from the group consisting of aluminum-containing compounds, zinc-containing compounds, or a mixture thereof, and a polymeric binder;
- depositing a second coating composition on a surface of the first coating composition, the second coating composition comprising second reducible metallic particles including iron-containing compounds, and a polymeric binder;
- depositing a third coating composition on a surface of the second coating composition, the third coating composition comprising third reducible metallic particles including aluminum-containing compounds, zinc-containing compounds, or a mixture thereof, and a polymeric binder,
- wherein the first and third reducible metallic particles are anodic relative to the second reducible metallic particles and the steel substrate, and wherein the first, second, and third coating compositions form an initial protective coating;
- treating the initial protective coating under conditions sufficient to remove substantially all of the polymeric binder of the first, second, and third coating compositions to form a residual layer comprising the first reducible metallic particles, the second reducible metallic particles, and the third reducible metallic particles;
- and
- treating the residual layer under conditions sufficient to cause the first, second, and third reducible metallic particles to form an alloy layer on the steel substrate surface.
4 more elements
Dependencies are inferred from the claim text.