Z720
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DESCRIPTION
Title of Invention
Precoated Metal Sheet Excellent in Conductivity and
5 Corrosion Resistance
Technical Field
[0001] The present invention relates to a precoated
metal sheet which is covered by a film which contains an
10 organic resin and particles of a non-oxide ceramic with
an electrical resistivity in a specific range at least at
part of its surface and which is therefore excellent in
conductivity and corrosion resistance.
15 Background Art
[0002] Below, the background art of the present
invention will be explained.
[0003] The post-coated metal sheet which is coated
after being shaped for use in home electrical appliances,
20 building materials, automobiles, etc. is being replaced
by precoated metal sheet which is covered with a colored
organic film. A precoated metal sheet, in most cases, has
excellent corrosion resistance and workability and
coating film adhesion due to the composite effects of the
25 metal itself (in the case of a plated metal sheet, the
plating film) and the chemical conversion at the layer
above it and, furthermore, the primer film at the layer
above that and, furthermore, in many cases is provided
with a colored organic film at its top surface, so the
30 coating operation after working can be eliminated and a
high productivity and beautiful appearance can be
obtained.
[0004] When press-forming a precoated metal sheet, the
film layer which is covered over the metal sheet is also
35 shaped, so the film is also required to have workability.
For this reason, a film layer based on a resin is the
general practice. The covering film of a precoated metal
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sheet is usually insulating. However, in precoated metal
sheets, a need for electroweldability at the time of
assembly of parts and a need for groundability,
electromagnetic shieldability, and other high
5 conductivity when used for home electrical appliances or
the housings for OA equipment have arisen. In response to
these demands for imparting conductivity to films, the
art has been proposed of covering a metal sheet with a
film which contains conductive particles to thereby
10 impart conductivity.
[0005] Among these, as art which uses conductive metal
particles, for example, PLT 1 proposes the art of
covering an aluminum or aluminum alloy substrate surface
with a resin film which contains aluminum or aluminum
15 alloy powder through a chromate film which strengthens
the corrosion resistance of the substrate or the adhesion
with the substrate so as to thereby obtain a precoated
aluminum or aluminum alloy material for home electric
appliance products or chassis parts which realizes both
20 excellent corrosion resistance and conductivity. The
amount of the aluminum or aluminum alloy powder which is
used for the resin film is described as being from 10 to
50 parts by weight with respect to 100 parts by weight of
the resin.
25 [0006] PLT 2 proposes the art of a galvannealed steel
sheet which has a resin-based conductive coating film
which contains zinc powder. It is stated that inclusion
of zinc powder in the coating film in 30 to 90 mass% is
preferable and that a coating film thickness of 2 to 30
30 ~m is preferable.
PLT 3 proposes the art of using a resin film which
contains 2 to 50 mass% of a metal powder, 1 to 50 mass%
of water, and 0.5 to 30 mass% of a surfactant as
essential ingredients and has a thickness of 5 ~m or less
35 so as to cover a metal sheet to raise its conductivity.
It is stated that as the metal powder, nickel powder is
suitable and as the coating for coating use, a water-
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based one is preferable.
[0007] Further, among the art for imparting
conductivity to a film, as art which enables use of
conductive particles other than metal particles, for
5 example, PLT 4 discloses the art of an organic composite
plated steel sheet which has, on a rust-prevention layer
mainly comprised of a chrome compound, an organic resin
coating of 0.5 to 20 ~ thickness containing 3 to 59 vol%
of a conductive powder. PLT 5 proposes the art of an
10 organic coated plated steel sheet which has a resin-based
film which contains 3 to 59 vol% of a conductive
material. As the conductive material, various metals and
their alloys, iron phosphate or ferrosilicon or other
iron compounds, etc. may be mentioned. PLT 6 discloses
15 the art of a conductive precoated metal sheet which has a
0.5 to 3 ~ thick coating film which contains any
conductive metal oxide. As the conductive metal oxide, it
is stated that one which includes zinc oxide of a
particle size of 5.0 ~m or less and an average 2 ~m in 40
20 to 50 parts by mass with respect to 100 parts by mass of
resin is desirable. PLT 7 proposes as a metal surface
coating agent which enables the formation of a
conductive, weldable corrosion resistant film after
curing at the metal surface, a water-based coating agent
25 which contains a specific organic binder in 10 to 30
mass% and a conductive material powder in 30 to 60 mass%.
As examples of conductive material powder which is
suitable for preparation of the present coating agent,
zinc, aluminum, graphite, carbon black, molybdenum
30 sulfide, and iron phosphate may be mentioned. PLT 8
proposes the art of automobile-use organic precoated
steel sheet which achieves both excellent corrosion
resistance and weldability by covering the surface of
zinc-based plate steel sheet or aluminum-based plated
35 steel sheet with a first layer film which strengthens the
adhesion with the plating and, through that, a resin-
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based second layer film which includes a rust-proofing
additive and a conductive pigment. The conductive pigment
is contained in the film in an amount of 5 to 70 vol%.
The film thickness is 1 to 30 ~. As a suitable
5 conductive pigment, a metal, alloy, conductive carbon,
iron phosphate, carbide, and semiconductor oxide may be
illustrated.
[0008] Further, as art which uses conductive ceramic
particles among conductive particles other than metal
10 particles, for example, PLT 9 proposes the art of a
conductive material-coated corrosion resistant metal
material which is excellent in corrosion resistance and
conductivity comprised of core metal which is covered by
a clad layer comprised of a corrosion resistant metal
15 and, furthermore, is covered over that by a surface
treatment layer comprised of at least one conductive
material selected from a carbon material, conductive
ceramic, and metal powder and of any resin which binds
the same.
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Citations List
Patent Literature
[0009] PLT 1 : Japanese Patent Publication No. 2000-
212764 Al
25 PLT 2: Japanese Patent Publication No. 55-17508 Al
PLT 3 : Japanese Patent Publication No. 2004-17455 Al
PLT 4 : Japanese Patent Publication No. 9-276788 Al
PLT 5 : Japanese Patent Publication No. 11-138095 Al
PLT 6 : Japanese Patent Publication No. 7-313930 Al
30 PLT 7 : Japanese Patent Publication No. 2003-513141 Al
PLT 8 : Japanese Patent Publication No. 2005-288730 Al
PLT 9 : Japanese Patent Publication No. 2003-268567 Al
Summary of Invention
35 Technical Problem
[0010] As explained ln the section on "Background
Art", in precoated metal sheets, a need for
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electroweldability at the time of assembly of parts and a
need for groundability and other higher conductivity when
used for household electrical appliances and parts office
automation equipment have arisen. Such a trend also
5 applies to inexpensive precoated metal sheet designed for
indoor household electrical appliances and interior
building materials. In this regard, if using the art such
as in PLT 1 or PLT 4 with the intent of solving these
problems, to obtain the desired corrosion resistance and
10 conductivity, it is necessary to use a chromate film or
chrome compound-containing rust-proofing layer as a
primer layer. This does not match the current need for
avoiding the effects of the toxic nature and
environmental load of hexavalent chrome.
15 [0011] If using zinc powder as conductive particles
like in PLT 2, using Fe-Si alloy, Fe-Co alloy, Fe-Mn
alloy, or other ferrous alloys as conductive particles in
PLT 4, or, further, using zinc or aluminum powder in PLT
7, if using plated steel sheet containing these In the
20 coating film in a usual moist environment indoors or
outdoors, there were the difficulties that a rust layer
or a thick oxide insulating layer would form on the
surface of the zinc powder or alloy, the powder and resin
would separate at their interface, and the conductivity
25 of the coating film would be lost.
[0012] In PLT 3 as well, use of nickel powder is
recommended. Nickel is excellent in relative water
resistance, so even if using a metal sheet which contains
this in a coating film in a usual moist environment
30 indoors or outdoors, the conductivity of the coating film
is held to a certain extent. However, the dependency on
overseas nickel resources is high. The changing
situations and oligopoly etc. of the producing countries
mean there is a risk of the resources not being able to
35 be stably and inexpensively acquired over the long term
in the future. Further, nickel has a specific gravity of
8.85 and is relatively heavy as conductive particles, so
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when using a roll coater or curtain coater etc. to coat
the coating on a metal sheet in mass production, the
nickel particles inside the coating rapidly settled and
did not easily enter the coating film resulting in the
5 desired conductivity often not being able to be obtained.
Furthermore, in PLT 3, use of a water-based coating is
recommended, but when using a water-based coating which
contains nickel particles, there was the difficulty that
with storage for several weeks or so, the surface layers
10 of the particles would oxidize and blue-green color
nickel oxide (II) (NiO) would form and float free in the
water thereby contaminating the coating.
[0013] Further, in PLT 7, a water-based coating-use
coating is used, so when using zinc and aluminum as
15 conductive particles, in the same way as the case of PLT
3, there was the defect that the water coexisting in the
water-based coating or film caused a rust layer to form
on the metal powder surface and caused the conductivity
to become inferior.
20 [0014] In this way, in the prior art, it is not easy
to obtain a precoated metal sheet which achieves both
sufficient conductivity and corrosion resistance without
jointly using a chromate primer layer (PLTs 1 and 4). If
using nickel particles as conductive particles,
25 industrial application is difficult due to the ease of
settling of nickel due to its high specific gravity,
unstable prices, etc. (PLT 3). It is not possible to
obtain a precoated metal sheet which maintains the
corrosion resistance of the precoated metal sheet and
30 enables use of a coloring pigment to color the sheet to a
desired color tone by keeping down the amount of addition
of conductive particles (PLTs 4 to 9), Further, if
selecting particles of base metals for which surface
oxide films easily form due to moisture, during the use
35 of the steel sheet, an oxide insulating layer or rust
layer is formed and sufficient conductivity cannot be
obtained (PLTs 2, 4, and 7). In this and other ways,
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there have been various problems.
[0015] As explained above, a precoated metal sheet is
being asked to provide both conductivity, more
specifically electroweldability at the time of assembly
5 of parts and groundability in the case of use for parts
of household electrical appliances or office automation
equipment, and corrosion resistance and aesthetic
appearance. To provide such a precoated metal sheet, it
has been necessary to provide the desired conductivity,
10 corrosion resistance, and coloring ability by a coloring
pigment by addition of a small amount of conductive
particles which are stable and maintain good
dispersability in the coating-use coating or during use
of the precoated metal sheet.
15 The present invention was made in consideration of
the above such problems and relates to a chromate-free
conductive, corrosion resistant precoated metal sheet
which is covered at least at part of its surface with a
film which contains a small amount of non-oxide ceramic
20 particles with an electrical resistivity limited to an
extremely low range.
Solution to Problem
[0016] The inventors engaged in intensive research for
25 achieving the above-mentioned such object and as a result
discovered that if forming on a metal surface a film
which contains a small amount of non-oxide ceramic
particles with an electrical resistivity of 0.lxl0-6 to
185xl0-6 ncm which are selected from borides, carbides,
30 nitrides, and silicides, which can be relatively
inexpensively obtained industrially, in an organic resin,
a conductive, corrosion resistant precoated metal sheet
which is excellent in all of conductivity, corrosion
resistance, and coloring ability by a coexisting coloring
35 pigment can be obtained.
[0017] The present invention was completed based on
the above findings and specifically is as follows:
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[0018] (1) A conductive, corrosion resistant precoated
metal sheet comprising a metal sheet on at least one
surface of which is formed a coating film (a) which
contains an organic resin (A) and non-oxide ceramic
5 particles (B) with a 25°C electrical resistivity of
0.lx10-6 to 185x10-6 Qcm selected from borides, carbides,
nitrides, non-oxide and silicides, a volume ratio of the
organic resin (A) and the non-oxide ceramic particles (B)
in the coating film (a) at 25°C being 90:10 to 99.9:0.1,
10 the organic resin (A) including a resin (A1) which
includes at least one type of functional group selected
from a carboxyl group and sulfonic acid group in a
structure of the resin (A1) or further a derivative (A2)
of that resin (A1).
15 [0019] (2) The conductive, corrosion resistant
precoated metal sheet as set forth in (1) characterized
in that the non-oxide ceramic particles (B) have a 25°C
electrical resistivity of 0.lx10-6 to 100x10-6 Qcm.
[0020] (3) The conductive, corrosion resistant
20 precoated metal sheet as set forth in (1) or (2)
characterized in that the coating film (a) has a
thickness of 2 to 10 ~.
[0021] (4) The conductive, corrosion resistant
precoated metal sheet as set forth in (1) or (2)
25 characterized in that the resin (A1) or derivative (A2)
of the resin (A1) further includes at least one type of
functional group selected from an ester group, urethane
group, and urea group in the structure of the resin (A1)
or the derivative (A2).
30 [0022] (5) The conductive, corrosion resistant
precoated metal sheet as set forth in (4) characterized
in that the resin (A1) is a polyurethane resin (Alu)
which includes a urea group in the structure of the
polyurethane resin (Alu).
35 [0023] (6) The conductive, corrosion resistant
precoated metal sheet as set forth in (5) characterized
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in that the resin (AI) is a mixed resin of a polyurethane
resin (Alu) which includes a urea group in the structure
of the polyurethane resin (Alu) and a polyester resin
(Ale) which includes an aromatic dicarboxylic acid as a
5 carboxylic acid component and includes a sulfonic acid
group in the structure of the polyester resin (Ale).
[0024] (7) The conductive, corrosion resistant
precoated metal sheet as set forth in (1) or (2)
characterized in that the derivative (A2) of the resin
10 (AI) is a resin (A2 si ) of the following general formula
(I) :
I General formula (I)
( I )
(wherein, the notation "AI" indicates the resin (AI), "Z"
indicates a C1 to Cg, No to N2' 00 to 02 hydrocarbon
15 chain, and the notation "Al-Z" indicates a covalent bond
of "AI" and "Z" through functional groups of the two.
Further, "-0-" is an ether bond, "-OH" is a hydroxyl
group, and "-X" is a C1 to C3 hydrolysable alkoxy group,
hydrolysable halogen group, or hydrolysable acetoxy
(10) The conductive, corrosion resistant
30
20 group, "-R" is a Cl to C3 alkyl group, "a", "b", "c", and
"d" which show the numbers of substituents are all
integers of 0 to 3, and a+b+c+d=3)
[0025] (8) The conductive, corrosion resistant
precoated metal sheet as set forth in (1) or (2)
25 characterized in that the organic resin (A) is a resin
which is cured by a curing agent (C).
[0026] (9) The conductive, corrosion resistant
precoated metal sheet as set forth in (8) characterized
in that the curing agent (C) contains a melamine resin
(Cl) .
[0027]
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precoated metal sheet as set forth in (1) or (2)
characterized in that the non-oxide ceramic particles (B)
are a boride ceramic M02B, MoB, MoB2, NbB, NbB2, TaB, TaB2,
TiB, TiB2' VB, VB2, W2Bs , or ZrB2; a carbide ceramic B4C,
5 MoC, M02C, Nb2C, NbC, SiC, Ta2C, TaC, TiC, V2C, VC, WC,
W2C, or ZrC; a nitride ceramic M02N, Nb2N, NbN, Ta2N, TiN,
or ZrN; a silicide ceramic Mo3Si, MoSi2, NbSi2, Ta2Si,
TaSi2, TiSi, TiSi2, VsSi3 , VSi2, W3Si, WSi2, ZrSi, or ZrSi2;
or a mixture of two or more types selected from these.
10 [0028] (11) The conductive, corrosion resistant
precoated metal sheet as set forth in (1) or (2)
characterized in that the coating film (a) is formed by
coating a water-based precoating-use composition.
15 Advantageous Effects of Invention
[0029] According to the present invention, by just
adding a small amount of a conductive material to a
coating film, it is possible to provide a precoated metal
sheet which gives a coating film conductivity realizing
20 sufficient groundability and weldability. Further, the
precoated metal sheet of the present invention also has
excellent corrosion resistance. Further, by adding a
coloring pigment in advance to the water-based or
solvent-based or other precoating-use composition for
25 obtaining the coating film of the present invention, it
is possible to easily provide a precoated metal sheet
which can be easily colored to the desired color tone.
Brief Description of Drawings
30 [0030] FIG. 1 is a schematic view of the cross-section
of a conductive, corrosion resistant precoated metal
sheet of the present invention.
Description of Embodiments
35 [0031] Below, the present invention will be explained
in detail.
[0032]
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The precoated metal sheet of the present invention is a
metal sheet which is covered at least at part of its
surface by a specific conductive coating film. According
to the application, both surfaces of the metal sheet may
be covered by the coating film or only a single surface
may be covered. Further, part of the surface may be
covered or the entire surface may be covered. The
locations of the metal sheet which are covered by the
coating film are superior in conductivity and corrosion
resistance.
[0033] As the metal forming the metal sheet which can
be used for the precoated metal sheet of the present
invention, for example, aluminum, titanium, zinc, copper,
nickel, steel, etc. may be used. The ingredients of these
metals are not particularly limited. For example, when
using steel, it may be ordinary steel or may be steel
containing chrome or other additive elements. However, if
using the metal sheet of the present invention for strong
ironing or deep drawing applications, in the case of each
metal, it is preferable to suitably control the types or
amounts of addition of the additive elements and the
metal structure so as to be suitable for strong ironing
or deep drawing. Further, when using steel sheet as the
metal sheet, the surface may have a covering plating
layer, but the type is not particularly limited. As the
applicable plating layer, for example, platings comprised
of any of zinc, aluminum, cobalt, tin, or nickel and
alloy platings which contain these metal elements and
further other metal elements or nonmetal elements etc.
may be mentioned. In particular, as zinc-based plating
layers, for example, platings comprised of zinc, alloy
platings of zinc and at least one of aluminum, cobalt,
tin, nickel, iron, chrome, titanium, magnesium, and
manganese, or various galvannealed platings which contain
further other metal elements or nonmetal elements (for
example, four-way alloy platings of zinc with aluminum,
magnesium, and silicon) may be mentioned, but the alloy
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ingredients other than the zinc are not particularly
limited. Further, these plating layers which contain
small amounts of different metal elements or impurities
such as cobalt, molybdenum, tungsten, nickel, titanium,
chromium, aluminum, manganese, iron, magnesium, lead,
bismuth, antimony, tin, copper, cadmium, arsenic, etc.
and which have silica, alumina, titania, and other
inorganic substances dispersed in them are included.
[0034] As aluminum-based plating layers, aluminum or
alloy platings of aluminum and at least one of silicon,
zinc, and magnesium (for example, alloy platings of
aluminum and silicon, alloy platings of aluminum and
zinc, three-way alloy platings of aluminum, silicon, and
magnesium), etc. may be mentioned.
[0035] Furthermore, composite platings of combinations
of the above platings and other types of platings, for
example, iron plating, iron and phosphorus alloy plating,
nickel plating, cobalt plating, etc. may also be used.
[0036] The method of forming the plating layer is not
particularly limited. For example, electroplating,
electroless plating, hot dipping, deposition plating,
dispersal plating, etc. may be used. The plating
treatment method may be either the continuous or batch
type. Further, when using steel sheet, as treatment after
plating, treatment for making the appearance uniform
after hot dipping, that is, zero spangle treatment,
treatment for reforming the plating layer, that is,
annealing treatment, temper rolling for adjusting the
surface conditions and material quality, etc. are
possible, but the present invention is not particularly
limited to these. Any may be used.
[0037]
The non-oxide ceramic particles (B) which are contained
in the coating film of the present invention must be a
boride ceramic, carbide ceramic, nitride ceramic, or
silicide ceramic with a 25°C electrical resistivity
10 (volume resistivity, specific electrical resistance) of
o.lx10-6 to 185x10-6 Ocm in range. The "non-oxide ceramic"
referred to here is a ceramic which is comprised of
elements or compounds not containing oxygen. Further, the
"boride ceramic", "carbide ceramic", "nitride ceramic",
15 and "silicide ceramic" referred to here are non-oxide
ceramic which respectively have boron B, carbon C,
nitrogen N, and silicon Si as main nonmetal component
elements. Among these, none can be found with a 25°C
electrical resistivity of less than 0.lx10-6 Ocm. Further,
20 if the 25°C electrical resistivity (volume resistivity,
specific electrical resistance) exceeds 185x10-6 Ocm, a
large amount must be added to impart sufficient
conductivity to the resin coating film. During use of the
precoated metal sheet of the present invention, a large
25 number of conduction paths for corrosive current which
pass through coating film are formed and the corrosion
resistance deteriorates, so this is not suitable.
Further, with a large amount of addition, the coating
film appearance is dominated by the color of the large
30 amount of conductive particles. Even if adding a coloring
pigment, the desired color tone cannot be colored to.
[0100] The non-oxide ceramic particles (B) which are
contained in the coating film of the present invention
are preferably a boride ceramic, carbide ceramic, nitride
35 ceramic, or silicide ceramic with a 25°C electrical
resistivity of 0.lx10-6 to 100x10-6 Ocm in range. These
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particles have a higher conductivity than particles with
a 25°C electrical resistivity of over 100xl0-6 ncm to
185xl0-6 ncm in range, so the amount of addition for
imparting sufficient conductivity to the resin coating
film may be made smaller and as a result the detrimental
effect on the corrosion resistance or coating film
appearance of the precoated metal sheet becomes smaller.
Note that, by way of reference, pure metal has an
electrical resistivity of 1.6xl0-6 ncm (Ag alone) to
185xl0-6 ncm (Mn alone) in range. It is learned that the
non-oxide ceramic which are used as conductive particles
in the present invention (electrical resistivity 0.lxl0-6
to 185xl0-6 ncm) have excellent conductivities of the same
extent as pure metals.
[0101] As the non-oxide ceramic which can be used in
the present invention, the following may be illustrated:
That is, as boride ceramic, borides of transition metals
or rare earth elements of Group IV (Ti, Zr, Hf), Group V
(V, Nb, Ta), or Group VI (Cr, Mo, W) of the Periodic
Table, as carbide ceramic, carbides of Group IV, Group V,
and Group VI transition metals and rare earth elements or
B or Si, as nitride ceramic, nitrides of Group IV, Group
V, and Group VI transition metals or rare earth elements,
as silicide ceramic, Group IV, Group V, and Group VI
transition metals or rare earth elements, or mixtures of
two or more types of compounds selected from these
borides, carbides, nitrides, and silicides or these
ceramic mixed with metal binding materials and sintered
to obtain cermets etc. may be illustrated.
[0102] When preparing the coating film (a) from the
water-based coating, the metal forming part of the cermet
preferably has a standard electrode potential of -0.3V or
more and water resistance. If the metal forming part of
the cermet has a standard electrode potential of less
than -0.3V, if the precoated metal sheet which has this
cermet powder in its coating film is used in a moist
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environment for a long period of time, a rust layer or a
thick oxide insulating layer may form on the surface of
the powder, the interface between the powder and resin
may separate, and the coating film may lose conductivity.
5 As examples of such water resistant cermet powder, WC12Co,
WC-12Ni, TiC-20TiN-15WC-10Mo2C-5Ni, etc. may be
mentioned. The standard electrode potentials of Co and Ni
are respectively -0.28V, -0.25V or both more precious
than -0.3V. Both metals have water resistance.
10 [0103] Among the non-oxide ceramic, Cr-based ceramic
are not available on the market due to concerns over the
environmental load. Further, most rare earth elementbased
and Hf-based ceramic are high in price. Therefore,
in the present invention, it is preferable to use a
15 boride, carbide, nitride, or silicide of elements other
than these in the group such as Ti, Zr, V, Nb, Ta, Mo, or
W or carbides of B or Si or mixtures of two or more types
selected from these.
[0104] Furthermore, from the viewpoint of the
20 existence of industrial products and the stable
availability in the domestic and foreign markets, price,
electrical resistivity, etc., the following non-oxide
ceramic are more preferred. That is, Mo2B (electrical
resistivity of 40x10-6 ncm) , MoB (same, 35x10-6 ncm) , MoB2
25 (same, 45x10-6 ncm) , NbB (same, 6.5x10-6 ncm) , NbB2 (same,
10x10-6 ncm) , TaB (same, 100x10-6 ncm) , TaB2 (same, 100x106
ncm) , TiB (same, 40x10-6 ncm) , TiB2 (same, 28x10-6 ncm) ,
VB (same, 35x10-6 ncm) , VB2 (same, 150x10-6 ncm) , W2Bs
(same, 80x10-6 ncm) , ZrB2 (same, 60x10-6 ncm) , B4C (same,
30 0.3x10-6 ncm) , MoC (same, 97x10-6 ncm) , M02C (same, 100x106
ncm) , Nb2C (same, 144x10-6 ncm) , NbC (same, 74x10-6 ncm) ,
SiC (same, 107x10-6 ncm) , Ta2C (same, 49x10-6 ncm) , TaC
(same, 30x10-6 ncm) , TiC (same, 180x10-6 ncm) , V2C (same,
140x10-6 ncm) , VC (same, 150x10-6 ncm) , wc (same, 80x10-6
35 ncm) , W2C (same, 80x10-6 ncm) , ZrC (same, 70x10-6 ncm) ,
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M02N (same, 20xl0-6 Ocm) , Nb2N (same, 142xl0-6 Ocm) , NbN
(same, 54xl0-6 Ocm) , Ta2N (same, 135xl0-6 Ocm) , TiN (same,
22xl0-6 Ocm) , ZrN (same, 14xl0-6 Ocm) , M03Si (same, 22xl0-6
Ocm) , MoSi2 (same, 22xl0-6 Ocm) , NbSi2 (same, 6.3xl0-6
Ocm) , Ta2Si (same, 124xl0-6 Ocm) , TaSi2 (same, 8. 5xl0-6
Ocm) , TiSi (same, 63xl0-6 Ocm) , TiSi2 (same, 123xl0-6
Ocm) , VsSi3 (same, 115xl0-6 Ocm) , VSi2 (same, 9.5xl0-6
Ocm) , W3Si (same, 93xl0-6 Ocm) , WSi2 (same, 33xl0-6 Ocm) ,
ZrSi (same, 49xl0-6 Ocm) , ZrSi2 (same, 76xl0-6 Ocm) , or
mixtures of two or more types selected from these are
preferably used.
[0105] Among these as well, non-oxide ceramic with an
electrical resistivity at 25°C of 0.lxl0-6 to 100xl0-6 Ocm
are particularly preferable. The reason is that these
have higher conductivity than non-oxide ceramic with a
25°C electrical resistivity of over 100xl0-6 Ocm to 185xl06
Ocm in range, so the amount of addition of particles
for imparting sufficient conductivity to the resin
coating film may be made smaller, only a few conduction
paths for corrosion current which pass through the
coating film are formed, and the corrosion resistance
does not drop much at all. Further, due to the addition
of the very small amount of particles, the coating film
appearance is not dominated by the color of the
conductive particles and even if adding a coloring
pigment, the desired colored tone can be easily colored
to.
[0106] The electrical resistivities which are given to
the non-oxide ceramic are respectively representative
values (documented values) of ceramic being sold and used
as industrial materials. These electrical resistivities
increase and decrease depending on the types or amounts
of impurity elements which entering into the crystal
lattices of the non-oxide ceramic, so when using the
ceramics in the present invention, for example, it is
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sufficient to use them after measuring the 25°C electrical
resistivity based on JIS K7194 by the four-terminal,
four-probe method using a Mitsubishi Chemical resistance
meter Loresta EP (Model MCP-T360) and ASP probes and the
constant current application method and confirming that
it is 0.lxl0-6 to 185xl0-6 Ocm in range.
[0107] The non-oxide ceramic particles (B) preferably
have particle shapes of spherical particles or quasi
spherical particles (for example, ellipsoid shapes, egg
shapes, rugby ball shapes, etc.) or polyhydral particles
(for example, soccer ball shapes, dice shapes, various
brilliant cut gemstone shapes, etc.) or other such shapes
close to spheres. Elongated shapes (for example, rod
shapes, needle shapes, fiber shapes, etc.) or planar
shapes (for example, flake shapes, plate shapes, thin
slice shapes, etc.) are not suitable for the applications
of the present invention since in the coating process,
they align in parallel on the coating surface or settle
near the interface of the substrate and coating and make
it difficult to form effective conduction paths passing
through the coating film in the thickness direction.
[0108] The non-oxide ceramic particles (B) are not
particularly limited in average particle size, but in the
precoating-use composition of the present invention, they
are preferably present as particles with a volume average
diameter of 0.05 to 8 ~m and are more preferably present
as particles with a volume average diameter of 0.2 to 5
~m. The dispersed particles having these volume average
diameters may be single particles or may be secondary
particles comprised of a plurality of single particles
strongly agglomerated so long as stably present in the
precoating-use composition in the process of production
of the precoating-use composition, at the time of storage
and transport, and in the process of coating the coat-use
substrate metal sheet (in the case of priming the metal
surface, the primed layer). In the process of coating the
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precoating-use composition on the substrate, there is no
problem even if the (B) particles agglomerate along with
the film formation and become larger in volume average
diameter in the coating film.
[0109] Note that, the "volume average diameter"
referred to here means the average size, based on volume,
which is found from the volume distribution data of the
particles. This is because while it is possible to find
this using any generally known particle size distribution
measurement method, it is preferable to use the average
value of the equivalent spherical diameter which is
measured by the Coulter method (aperture electrical
resistance method). The reason is that the Coulter
method, compared with other methods of measurement of the
distribution of particle size (calculation from volume
distribution obtained by laser diffraction scattering
method, conversion of circular area equivalent diameter
distribution obtained by image analysis method to volume
distribution, calculation from mass distribution obtained
by centrifugal precipitation method, etc.), enables
accurate, high precision measurement with almost no
differences in measurement values due to the manufacturer
or model of the measuring equipment. In the Coulter
method, test particles are suspended in an electrolyte
aqueous solution, a constant current is run through an
aperture of a glass tube, and particles pass through the
aperture by negative voltage. When a particle passes
through the aperture, the volume of the electrolyte
aqueous solution which the particle displaces (= volume
of particle) causes the electrical resistance at the
aperture to increase. If applying a constant current, the
change in resistance at the time of passage of a particle
is reflected in a change in voltage pulse, so by counting
this voltage pulse height one at a time, it is possible
to directly measure the volume of the individual
particles. Particles are usually irregular in shape, so a
sphere of a volume the same as a particle is assumed and
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the size of that sphere (= equivalent spherical diameter)
is converted to. The method of measurement of the
equivalent spherical diameter by such a Coulter method is
well known and, for example, is described in detail in
5 the web page of the official Internet site of Beckman
Coulter
[http://www.beckmancoulter.co.jp/product/product03/
Multisizer3.html (Precision Particle Size Distribution
Measurement System Multisizer 3).
10 [0110] Non-oxide ceramic particles with a volume
average diameter of less than 0.05 ~m are not only more
expensive than larger non-oxide ceramic particles, but
also have extremely large specific areas, so, for
example, even if using a wet dispersant in a water-based
15 or organic solvent-based precoating-use composition, it
is difficult to wet the particle surface and disperse the
particles. Further, non-oxide ceramic particles with a
volume average diameter of over 8 ~m settle faster and
more easily in a water-based or organic solvent-based
20 precoating-use composition than smaller non-oxide ceramic
particles (clear from Stokes equation). Therefore,
sometimes it is difficult to secure stability of
dispersion and particles settle, agglomerate, and
solidify in a short time.
25 [0111] When defining the volume average diameter of
the non-oxide ceramic particles (B) which are dispersed
in the coating film (a) as "c" ~m and the thickness of
the coating film (a) as "b" ~m, the relation of
0.5~c/b~1.5 is preferably satisfied. FIG. 1 is a schematic
30 view of the cross-section of the conductive, corrosion
resistant precoated metal sheet of the present invention.
(A) indicates an organic resin, (B), (B') indicate nonoxide
ceramic particles, (C) indicates parts cross-linked
by a curing agent, and (y) indicates the metal sheet. (B)
35 indicates particles with ratios c/b of particle size to
thickness of 0.5 or more. In this case, conductivity in
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the thickness direction is secured. (B I
) indicates
particles with ratios c/b of particle size to thickness
of less than 0.5. In this case, sometimes conductivity is
not sufficiently secured. If the ratios c/b of particle
5 size to thickness exceed 1.5, sometimes the corrosion
resistance and the workability fall.
[0112]
In the case of a water-based precoating-use composition,
the organic resin (A) preferably contains a polyphenol
10 compound as a rust preventive agent. A polyphenol
compound is a compound which has two or more phenolic
hydroxyl groups bonded to a benzene ring or its
condensate. It can be bonded to a metal surface by a
chelation action by coordinate bonds and, further, can be
15 bonded with hydrophilic groups of a coexisting waterbased
resin by hydrogen bonds. By blending in such a
polyphenol compound, the adhesion between the substrate
constituted by the metal sheet (in the case of priming,
the primed layer) and the coating film (a) and the
20 flexibility of the coating time at the time of the sheet
being worked are strikingly improved and, in turn, the
corrosion resistance of the worked part is also improved.
[0113] The polyphenol compound which is used in the
present invention is not particularly limited so long as
25 it can be uniformly dissolved or finely dispersed in the
water-based precoating-use composition which is used for
forming the covering coating film. Even if not water
soluble or water dispersable, it may be used so long as
able to penetrate between the hydrophobic chains of the
30 resin (A1) coexisting in the water-based precoating-use
composition (~) and able to uniformly finely disperse.
[0114] As the compound which has two or more phenolic
hydroxyl groups bonded with a benzene ring, for example,
gallic acid, pyrogallol, catechol, etc. may be mentioned.
35 The condensate of the compound which has two or more
phenolic hydroxyl groups bonded with a benzene ring is
not particularly limited, but, for example, polyphenol
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compounds etc. which are usually called tannic acid and
which are widely distributed in the plant kingdom may be
mentioned. "Tannic acid" is the general name for the
aromatic compounds, widely distributed in the plant
kingdom, of a complicated structure which have a large
number of phenolic hydroxyl groups. The tannic acid may
be a hydrolysable tannic acid or a condensation type
tannic acid. The tannic acid is not particularly limited.
For example, hamamelis tannin, persimmon tannin, tea
tannin, sumac gallnut tannin, gallnut tannin, myrobalan
tannin, divi divi tannin, algarovilla tannin, valonia
tannin, catechin tannin, etc. may be mentioned. The
polyphenol compound may be used as single types or may be
used jointly as two or more types.
[0115] The polyphenol compound preferably is contained
in 1 to 100 parts by mass with respect to 100 parts by
mass of the organic resin (A). If less than 1 part by
mass, the amount of the polyphenol compound is
insufficient, so a sufficient coating film adhesion
cannot be obtained or as a result the worked parts may
become insufficient in corrosion resistance. If over 100
parts by mass, the amount of the polyphenol compound in
the coating film is too great and therefore the coating
film adhesion at the time of being worked, the coating
film flexibility, and the corrosion resistance of the
worked parts fall or the stability of the precoating-use
composition is sometimes lowered.
[0116] In the case of a water-based and organic
solvent-based precoating-use composition, the organic
resin (A) preferably contains, as a rust preventive
agent, one or more types of compounds which are selected
from the group of phosphoric acid and hexafluorometal
acids. These phosphoric acid and hexafluorometal acids
may be used alone or may be used jointly. These acids
activate the metal surface by etching and promote the
action of the silane coupling agent (s) or the polyphenol
compound on the metal surface. Further, phosphoric acid
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has, in addition to the above action, the action of
forming a phosphate layer on a metal surface so as to
passivate it, so improves the corrosion resistance.
Further, hexafluorometal acids, in addition to the above
action, enable the formation of a stable thin film
containing oxides of a metal supplied from
hexafluorometal acids on the metal surface on which the
coating film is formed and, as a result, improves the
corrosion resistance. The phosphoric acid which can be
used in the present invention is not particularly
limited. For example, o-phosphoric acid, p-phosphoric
acid (linear polymer of polymerization degree of 0phosphoric
acid of up to 6 alone or mixture of two or
more types of these), or m-phosphoric acid (cyclic
polymer of polymerization degree of o-phosphoric acid of
3 to 6 alone or a mixture of two or more types of these)
may be mentioned. The phosphoric acid may be used in
single types or may be jointly used as two or more types.
A polyphosphoric acid with a polymerization degree larger
than 2 can be easily industrially obtained as a mixture
of polyphosphoric acids with several polymerization
degrees, so in the present invention, such a mixture may
be used.
[0117] The hexafluorometal acids which can be used in
the present invention are not particularly limited. For
example, hexafluoro- phosphoric acid, hexafluorotitanic
acid, hexafluorozirconic acid, hexafluorosilicic acid,
hexafluoroniobic acid, hexafluoroantimonic acid, or their
ammonium salts, potassium salts, sodium salts, calcium
salts, magnesium salts, etc. may be mentioned.
Hexafluorometal acids, in the above way, form stable thin
films which contain metal oxides on metal surfaces, but
to give rise to such effects, preferably include as the
metals one or two or more elements which are selected
from the group comprised of Ti, Si, Zr, and Nb. The
hexafluorometal acids may be used as single types or may
be jointly used as two or more types.
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[0118] One or more acids selected from the group of
phosphoric acid and hexafluorometal acids are preferably
contained in 0.1 to 100 parts by mass with respect to 100
parts by mass of the organic resin (A). If less than 0.1
part by mass, the action by these acids will be
insufficient, so the corrosion resistance will sometimes
drop. If over 100 parts by mass, the coating film will
become fragile and cohesive failure of the coating film
may cause the coating film adhesion when being worked and
the flexibility of the coating film to drop.
[0119] In the case of a water-based and organic
solvent-based precoating-use composition, the organic
resin (A) preferably contains a phosphate compound as a
rust preventive agent. By blending in this phosphate
compound, when forming a coating film, an insoluble
phosphate thin film can be formed on the metal surface.
That is, if the melt dissolves due to the phosphoric acid
ions of the phosphate, the pH will rise at the metal
surface and, as a result, a settled film of the phosphate
will be formed and the corrosion resistance will be
improved.
[0120] The phosphate compound which can be used in the
present invention is not particularly limited. For
example, o-phosphoric acid, p-phosphoric acid (linear
polymer of o-phosphoric acid up to polymerization degree
6 alone or mixture of two or more types of the same), mphosphoric
acid (cyclic polymer of o-phosphoric acid up
to polymerization degree 3 to 6 alone or mixture of two
or more types of the same), or other metal salts, phytic
acid, phosphonic acid, phosphinic acid, and other organic
metal salts may be mentioned. The type of cation is not
particularly limited. For example, Cu, Co, Fe, Mn, Sn, V,
Mg, Ba, Al, Ca, Sr, Nb, Y, Ni, Zn, etc. may be mentioned,
but Mg, Mn, Al, Ca, and Ni are preferably used. The
phosphate compound may be used alone as single types or
may be jointly used as two or more types.
[0121] The phosphate compound is preferably contained
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in 0.1 to 100 parts by mass with respect to 100 parts by
mass of the organic resin (A). If less than 0.1 part by
mass, the action of the phosphate compound is
insufficient, so the corrosion resistance sometimes
5 falls. If over 100 part by mass, the coating film becomes
fragile and cohesive failure of the coating film
sometimes cause the coating film adhesion when worked and
the coating film flexibility to fall.
[0122] In the case of a water-based and organic
10 solvent-based precoating-use composition, the organic
resin (A) preferably contains, as a rust preventive
agent, metal oxide particles comprised of at least one
type of metal element selected from the group of Si, Ti,
AI, and Zr. By blending in these metal oxide particles,
15 the corrosion resistance can be enhanced more.
[0123] As the metal oxide particles which can be used
in the present invention, for example, silica particles,
alumina particles, titania particles, zirconia particles,
etc. may be mentioned. Ones with a volume average
20 diameter of 1 to 300 nm or so are preferable. These may
be used alone or may be jointly used in two or more
types. Among these, silica particles are added when both
improvement of the corrosion resistance of the coating
and strengthening and toughening are required. The silica
25 particles are not particularly limited, but the coating
film is a thin film, so primary particle size 3 to 50 nm
colloidal silica, fumed silica, or other silica particles
are preferred.
[0124] The metal oxide particles are preferably
30 contained in 1 to 100 parts by mass with respect to 100
parts by mass of the organic resin (A). If less than 1
part by mass, the amount of the metal oxide particles is
insufficient, so sometimes the effect of raising the
corrosion resistance cannot be obtained. If over 100
35 parts by mass, the coating film becomes fragile and
coating film cohesive failure sometimes causes a drop in
the coating film adhesion at the time of working and the
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flexibility of the coating film.
[0125] The above various types of rust preventive
agents are preferably dissolved or dispersed and
stabilized in suitable amounts in the precoating-use
composition (p) and introduced into the organic resin (A)
in the coating film (a) in advance.
[0126]
The coating film (a) may further contain a coloring
pigment. The type of the coloring pigment is not
particularly limited. As an inorganic coloring pigment,
for example, titanium dioxide powder, alumina powder,
Venetian Red, Burnt Sienna, and other iron oxide powder,
zinc oxide powder, carbon black, graphite powder, coal
dust, talc powder, Cadmium Yellow, Cadmium Red, Chrome
Yellow, Cobalt Yellow, Cobalt Blue, Cerulean Blue, Cobalt
Green, etc. may be used. As the organic coloring pigment,
for example, Phthalocyanine Blue, Phthalocyanine Green,
quinacridone, perylene, anthrapyrimidine, Carbazole
Violet, anthrapyridine, Azo Orange, Flavanthrone Yellow,
Isoindoline Yellow, Azo Yellow, Indanthrone Blue,
Dibromanzathrone Red, Perylene Red, Azo Red,
Anthraquinone Red, etc. may be used. Further, if able to
give the coating film (a) the necessary coloring or
gloss, feeling, and other appearance, for example, copper
powder, tin powder, nickel powder, bronze (Cu-Sn-based
alloy) powder, or other water resistant metal particles
may be used as coloring pigments. Even aluminum powder or
zinc powder etc. which are somewhat inferior in water
resistance can be used as coloring pigments. Further,
aluminum flakes, mica flakes, sheet-like iron oxide,
glass flakes, and other flake-like bright materials, mica
powder, metal coating mica powder, titanium dioxide
coated mica powder, titanium dioxide coated glass powder,
or other powdered bright materials can also be used.
[0127]