Title of the Invention:
PROCESS FOR PRODUCING ENVIRONMENTALLY-FRIENDLY STEEL
5 SHEET FOR CONTAINER MATERIAL, ENVIRONMENTALLY-FRIENDLY
STEEL SHEET FOR CONTAINER MATERIAL, AND LAMINATED AND
PRE-COATED STEEL SHEET FOR CONTAINER MATERIAL USING THE
SAME
10 Technical Field
[0001.]
The present invention relates to a surface-treated
metal material and a method of surface-treating the metal
material. More specifically, the present invention
15 relates to an environmentally-friendly steel sheet for a
container, wherein a steel sheet can be primer-treated
without using a treatment solution containing chrome,
fluorine, or nitrate nitrogen, and a process for
producing the same.
20
BACKGROUND ART
[0002]
As the treatment for improving the adhesion between
an organic film and a metal material such as steel sheet,
25 zinc-based plated steel sheet, zinc-alloy sheeI, tinbased
plated steel sheet and aluminum alloy sheet, there
have heretofore been known chromate treatment, phosphate
treatment, silane coupling treatment, etc. Among these,
the chromate treatment has been broadly utilized in the
30 fields of home electrical appliances, building materials,
vehicles, metal containers, etc., due to its superior
corrosion resistance and adhesion. However, there has
been pointed out the possibility of the toxic substance
of hexavalent chrome contaminating the soil, etc., by the
35 leaching thereof into the soil at the time of the
disposal of the chromate-treated products. Accordingly,
the industries mainly in Europe, are ready to eliminate
2
the chromate treatment at the present stage.
[00031
In the field of metal materials to be used for
containers, a certain type of chromate treatment method
5 is being utilized, such that a tin-plated steel sheet is
treated by cathodic electrolysis in an aqueous solution
of sodium bichromate, or a steel sheet is treated by
cathodic electrolysis in an aqueous solution of fluorinecontaining
anhydrous chromic acid, so as not to leave
10 hexavalent chrome in the resultant film. However, even
in the case of the chromate treatment of a type where the
treated layer does not include hexavalent chrome, the
treatment solution to be used therefor contains the
hexavalent chrome, and accordingly, the hexavalent chrome
15 has to be rendered harmless for the treatment or disposal
of the wastewater and gas emissions. For this reason,
from the viewpoint of the environmental load, a surface
treatment is desirable such that the treatment solution
does not include hexavalent chrome either.
20 From this viewpoint, in order to make a treatment
solution hexavalent chromium--free., attempts to eliminate
chromium have come to attract attention, and such
chromium-free attempts include investigation on the
removal of chromium from a coating film or plating per
25 se, a coat-Lug film or alternative plating whicli is
alternative to chromium or chromium plating.
Further, with respect to fluorine, boron, nitrate
nitrogen, etc,, are also not preferable from the
viewpoint of the environmental load. In the future, the
30 industries will be encountered with toughened emission
standards therefor. Therefore, the treatment solutions
for metal materials to be used for containers may
preferably be those which do not contain the substances
as described above,
35 [0004.]
Therefore, as one measure for reducing the
environmental load, there is elimination of the use of
3
chrome. Patent Document 1 discloses an example of the
method of surface-treating a tin-plated steel can
superior in corrosion resistance and coating adhesion,
wherein a container material is chrome-free surface-
5 treated by providing, on a tin-plated surface of a tinplated
steel sheet, an organic-inorganic composite
coating comprising an organic compound main comprising
carbon and an inorganic phosphorus compound. Patent
Document 2 discloses, as a surface treatment solution for
10 an aluminum can or tin-plated DI (drawing and ironing)
can prior to the coating and printing thereof, an example
of the surface treatment solution for DI can, which
contains at least one kind of phosphoric acid ions and a
zirconium compound and titanium compound, and contains an
15 oxidizing agent and at least one kind of fluoric acid and
a fluoride.
[0005]
Conventionally, the metal containers to be used for
beverage can and food can applications have generally
20 been treated so as to bake the coatings at the inside and
outside surfaces of the cans, after the manufacturing of
the cans. In recent years, as the metal materials to be
used for beverage cans or food cans, there have been
increasingly used a steel sheet with a film which has
25 been hot-laminated on the steel sheet in advari e, and a
pre-coated steel sheet comprising a steel sheet which has
been subjected to a coating treatment including printing
and baking, in advance.
(00061
30 However, in the can manufacturing using DI or DRD
(drawing and redrawing), an ironing force acts on the can
wall, so in a case where a can is manufactured by using a
laminated steel sheet or coating pre-coated steel sheet
type of metal material for container, if the adhesive
35 strength between the resin coating and the steel sheet is
not sufficient, there is caused a problem such that the
resin coating will easily be peeled off. Further, in the
4
sterilization (i.e., retort treatment) which is to be
performed after filling of the can with a content, water
in the content sometimes permeates the resin coating
under the high temperature and high pressure conditions,
5 and the adhesion is liable to be decreased. Accordingly,
even in the development of the chromium-free type steel
sheet for container material, it is necessary to attain
an excellent adhesion between the resin coating and the
steel sheet.
10 [0007]
With respect to such a requirement for the container
materials, as disclosed in Patent Document 3, the present
inventors have developed a chromium-free steel sheet for
a container material having an excellent adhesion in
15 which a zirconium compound-containing coating film is
formed on a tin-plated steel sheet, and have developed a
steel sheet for container material having an adhesion
which is equal to or greater than that of the
conventional chromate treatment. However, the invention
20 disclosed in Patent Document 3 had a drawback such that,
in the electrolytic treatment therefor, it is necessary
to finely regulate the electrolytic conditions during the
treatment in order to maintain the coating amount in an
appropriate range.
25
Prior Art Documents
Patent Documents
°[0008]
[Patent Document 1] JP-A (Japanese Unexamined
30 Patent Publication; Kokai) No. 11-264075
[Patent Document 2] JP-A No. 7-48677
[Patent Document 3] JP-A No. 2009-68108
[Summary of the Invention]
[Problem to Be Solved by the Invention]
35 [0009]
An object of the present invention is to provide a
chromium-free steel sheet for a container material having
5
excellent characteristics (for example, adhesion with an
organic resin coating such as laminate film or coating
material; and resistance to iron dissolution after dent
impact), which are equal or comparable to those of the
5 conventional steel sheets for container material which
have been subjected to chromium plating or chromate
coating treatment.
Another object of the present invention is to
provide a process for producing a chromium-free steel
10 sheet for a container material having excellent
characteristics as mentioned above, which also enables
easy and stable production of the chromium-free steel
sheet.
15 Means for Solving the Problem
(00101
As a result of earnest study on chromium-free
processes which do not use chromium in the plating or in
the coating film to be disposed thereon for the purpose
20 of solving the above problem, the present inventors have
found a process which is environmentally friendly, and
can easily and stably produce a chromium-free steel sheet
for a container material having an excellent adhesion, as
describe hereinbelow.
25 More specifically, the present invention relates to
a process for producing an environmentally friendly steel
sheet for a container material, comprising a step of
subjecting a tin-plated steel sheet to a cathodic
electrolytic coating treatment in a treatment solution
30 not containing a chromium compound, fluorine, or a
nitrate nitrogen, wherein:
a tin oxide layer present on a tin-plated steel
sheet before the cathodic electrolytic coating treatment
is removed by a cathodic electrolytic treatment in an
35 aqueous solution containing sodium carbonate or sodium
hydrogen carbonate, or by an immersion treatment in an
aqueous sulfuric acid solution, so as to provide a
6
thickness of 0 mC/cm2 or more and 3.5 mC/cm2 or less as
measured by electrolytic stripping method, and then;
a coating film having a film coating amount
converted to zirconium of 0.1 mg/m2 or more and 20 mg/m2
5 or less is formed by a cathodic electrolytic coating
treatment in an aqueous solution of an alkali metal
sulfate containing a zirconium compound with an electric
conductivity of 0.2 S/m or more and 6.0 S/m or less and a
pH of 1.5 or more and 2.5 or less.
10 The present invention also provides an
environmentally friendly steel sheet for a container
material, comprising a tin-plated steel sheet and a
zirconium compound-containing coating film disposed
thereon, wherein a tin oxide layer present on the tin-
15 plated steel sheet is 0 mC/cm2 or more and 3.5 mC/cm2 or
less, and the zirconium compound-containing coating film
has a film coating amount converted to zirconium of 0.1
mg/m2 or more and 20 mg/m2 or less.
According to the discovery and investigation of the
20 present inventors, it is presumed that, in the invention
disclosed in Patent Document 3, the electrolytic
condition in the electrolytic treatment in this document
is required to be finely regulated so as to maintain the
coating amount in an appropriate range, because the
25 coating amount of the coating film tends to be increased
abruptly, with respect to an increase in the current
density (see Fig. 2 and Fig. 3 appearing hereinafter).
it is also presumed that such a change in the coating
amount of the coating film is caused by a pH change
30 (i.e., an increase in the pH) due to the hydrogen gas
release in the vicinity of the electrode for
electrolysis, to thereby cause a change in the coating
amount of the coating film (i.e., an increase in the
coating amount of the coating film). In addition, it is
35 presumed that the progress of the film coating process
(i.e., consumption of zirconium) per se causes an
increase in the pH, and this pH increase accelerates the
7
above pH change.
As a result of such phenomena, in the prior art, it
presumed to be indispensable, to finely regulate the
electrolytic conditions in response to the variation in
5 the process conditions (such as sheet width, line speed,
and liquid temperature) so as to maintain the coating
amount in an appropriate range, by suitably controlling
the above tendency to cause the "abrupt increase in the
coating amount of coating film."
10 In contrast thereto, the present inventors have
found that a large amount of alkali metal ions such as Na+
and K+ in the electrolytic solution neutralize OH- ions in
the vicinity of the cathode, so as to provide a tendency
of relieving (or reducing) the local pH variation in the
15 vicinity of the cathode, and on the basis of the
tendency, the zirconium oxide ions (ZrO2+) are stabilized.
Based on such a discovery, the present inventors have
completed the present invention.
According to the present invention, a curve showing
20 "changes in the film coating amount converted to
zirconium" corresponding to the pH change in the vicinity
of the electrode for electrolysis can be smoothened (as
shown in the graphs of Fig. 2 and Fig. 3 appearing
hereinafter). Therefore, it is presumed that, according
25 to the present invention, "the film coating amount
converted to zirconium" can stably be controlled, so as
to enable the stable film deposition treatment.
In other words, the present invention has a
characteristic such that ZrO2 to be deposited on a plated
30 surface is added (actually, zirconium sulfate is added)
by using an easily electrolyzable "aqueous solution of an
alkali metal sulfate" as a main component.
The present invention may include the following
35 embodiments.
[1] A process for producing an environmentally
friendly steel sheet for a container material, comprising
8
a step of subjecting a tin-plated steel sheet to a
cathodic electrolytic coating treatment in a treatment
solution not containing a chromium compound, fluorine, or
a nitrate nitrogen, wherein:
5 a tin oxide layer present on a tin-plated steel
sheet before the cathodic electrolytic coating treatment
is removed by a cathodic electrolytic treatment in an
aqueous solution containing sodium carbonate or sodium
hydrogen carbonate, or by an immersion treatment in an
10 aqueous sulfuric acid solution, so as to provide a
thickness of 0 mC/cm2 or more and 3.5 mC/cm2 or less as
measured by electrolytic stripping method., and then;
a coating film having a film coating amount
converted to zirconium of 0.1 mg/m2 or more and 20 mg/m2
15 or less is formed by a cathodic electrolytic coating
treatment in an aqueous solution of an alkali metal
sulfate containing a zirconium compound with an electric
conductivity of 0.2 S/m or more and 6.0 S/m or less and a
pH of 1.5 or more and 2.5 or less.
20 [2] The process for producing an environmentally
friendly steel sheet for a container material according
to [1], wherein the concentration of zirconium contained
in the aqueous solution of an alkali metal sulfate is 10
mg/L or more and 2000 mg/L or less.
25 [3] The process for producing an environmentally
friendly steel sheet for a container material according
to [1] or [2], wherein the alkali metal sulfate is sodium
sulfate.
[4] The process for producing an environmentally
30 friendly steel sheet for a container material according
to [1] or [2], wherein the alkali metal sulfate is
potassium sulfate.
[5] The process for producing an environmentally
friendly steel sheet for a container material according
35 to [1.] or [2], wherein the concentration of the alkali
metal sulfate contained in the aqueous solution of the
alkali metal. sulfate is 0.1 mass % or more and 8.0 mass %
9
or less,
[6] An environmentally friendly steel sheet for a
container material, comprising a tin-plated steel sheet
and a zirconium compound-containing coating film disposed
5 thereon,
wherein a tin oxide layer present on the tin-plated
steel sheet is 0 mC/cm2 or more and 3.5 mC/cm2 or less,
and the zirconium compound-containing coating film has a
film coating amount converted to zirconium of 0.1 mg/m2 or
10 more and 20 mg/m2 or less.
[7] An environmentally friendly laminated steel
sheet for a container material, comprising the steel
sheet for a container material according to [6].
[8] An environmentally friendly precoated steel
15 sheet for a container material, comprising the steel
sheet for a container material according to [6].
Effect of the Invention
[0011]
20 The steel sheet for a container material having a
light environmental load which has been produced by the
production process according to the present invention has
an adhesion with an organic resin coating film such as a
laminated film or a coating material, and also has an
25 excellent performance as a chromium-free steel sheet for
a container material such as resistance to iron
dissolution after dent impact, which is equal or
comparable to that of the conventional chromium-treated
steel sheet for a container material. In addition, such
30 a steel sheet for a container material can be produced
easily and stably, and therefore the industrial value
thereof is very high.
Brief Description of the Drawings
35 [0012]
[Fig. 1]
Fig. 1 is a graph showing a relationship between the
- 10 -
amount (amount of removal due to electrolytic stripping)
of tin oxide on a tin-plated surface, and coating
material adhesion (T-peel strength) of a tin-plated steel
sheet which has been coated with a film of zirconium
5 compound.
[Fig. 2]
Fig. 2 is a graph showing a relationship between the
current density during an electrolytic treatment and the
film coating amount converted to zirconium of a primer
10 coating film in the case of a conventional zirconium
sulfate treatment solution, and in the case of a sodium
sulfate treatment solution containing a zirconium
compound according to the present invention.
[Fig. 3]
15 Fig. 3 is a graph showing a relationship between the
pH of a treatment solution and the film coating amount
converted to zirconium of a primer coating film disposed
on a tin-plated steel sheet after electrolytic treatment,
in the case of a conventional zirconium sulfate treatment
20 solution, and in the case of a sodium sulfate treatment
solution containing a zirconium compound according to the
present invention,
[Fig. 4]
Fig. 4 is a graph showing a relationship between the
25 film coating amount converted to zirconium of primer
coating film, and the coating material adhesion (T-peel
strength) of a tin-plated steel sheet, which has been
-subjected to an electrolytic treatment with a sodium
sulfate treatment solution containing a zirconium
30 compound according to the present invention.
[Fig. 5]
Fig. 5 is a graph showing a relationship between the
zirconium concentration of an aqueous sodium sulfate
solution containing a zirconium compound according to the
35 present invention, and the film coating amount converted
to zirconium of a coating film containing a zirconium
compound.
11 -
[Fig. 6]
Fig. 6 is a graph showing a relationship between the
zirconium concentration, and the storage stability of a
treatment solution according to the present invention.
5 [Fig. 7]
Fig. 7 is a graph showing a relationship between the
electric conductivity of a treatment solution, and the
rectifier voltage during electrolysis, when sodium
sulfate treatment solution containing a zirconium
10 compound having different electric conductivities
according to the present invention are electrolyzed while
changing the current density.
[Fig. 8]
Fig. 8 is a graph showing a relationship between the
15 electric conductivity of a treatment solution, and the
film coating amount converted to zirconium of a primer
coating film, when each of a sodium sulfate treatment
solution containing a zirconium compound, or a potassium
sulfate treatment solution containing a zirconium
20 compound according to the present invention having
different electric conductivities is electrolyzed.
[Fig. 9]
Fig. 9 is a graph showing a relationship between the
pH of a treatment solution, and the film coating amount
25 converted to zirconium of a primer coating film, when
sodium sulfate treatment solutions containing a zirconium
compound according to the present invention having
different pH are electrolyzed.
[Fig. 10]
30 Fig. 10 is a graph which shows the storage stability
of sodium sulfate treatment solutions containing a
zirconium compound according to the present invention
having different pH which have been allowed to stand at
40°C for 2 weeks, and shows a relationship between the pH
35 and the results of storage stability evaluation of the
solutions.
[Fig. 11]
- 12 -
Fig. 11 is a graph showing a relationship between
the sodium sulfate concentration (mass %) and the
electric conductivity of a solution, wherein zirconium
sulfate has been added to an aqueous sodium sulfate
5 solution so as to provide a zirconium concentration of 10
mg/L, and sulfuric acid is added thereto so that pH of
the solution has been adjusted to 1,5 or 2.5.
[Fig. 12]
Fig. 12 is a graph showing a relationship between a
10 sodium sulfate concentration (mass %), and the electric
conductivity of a treatment solution, wherein zirconium
sulfate has been added to an aqueous sodium sulfate
solution so as to provide a zirconium concentration of
2000 mg/L, and sulfuric acid is added thereto so that pH
15 of the solution has been adjusted to 1.5 or 2.5.
[Figs 13]
Fig. 13 is a graph showing a relationship between
the current density during electrolytic treatment, and
the film coating amount converted to zirconium of a
20 primer coating film in the case of a conventional
zirconium sulfate treatment solution, and in the case of
a sodium sulfate treatment solution containing a
zirconium compound according to the present invention.
The graph shows that the zirconium deposition amount is
25 stable, even if the zirconium concentration is changed.
Modes for Carrying Out the Invention
10013]
The present invention relates to a process for
30 producing a steel sheet for a container material, wherein
a tin-plated steel sheet is subjected to a cathodic
electrolytic coating treatment in a treatment solution
which does not contain a chromium compound, fluorine, or
nitrate nitrogen. The steel sheet for a container
35 material having a small environmental load which has been
obtained by the present invention is a steel sheet
wherein a cathodic electrolytic coating treatment layer
- 13 -
comprising a zirconium compound has been formed on the
surface of a tin-plated steel sheet.
The present invention specifically relates to a
process for producing a steel sheet for a container
5 material having a small environmental load, wherein a
cathodic electrolytic coating treatment film can be
obtained by cathodic electrolytic coating treatment in an
aqueous alkali metal sulfate solution comprising a
zirconium compound which does not contain a chromium
10 compound, fluorine or nitrate nitrogen.
The best mode for carrying out the invention will be
explained below,
[0014]
15 The type of the steel sheet to be used in the
present invention is not particularly limited. It is
possible to use a steel sheet which is the same as the
steel sheet which has been used for materials for
containers.
20 [0015]
The type of the steel sheet to be used in the
cathodic electrolytic coating treatment according to the
present invention is not particularly limited. However,
25 a tin-plated steel sheet may be most suitable s the
environmentally friendly steel sheet for a container
material according to the present invention, in view of
the reasons such as good record of use in canning
applications, freedom from problems in food safety and
30 sanitation, superiority in corrosion resistance,
superiority in formability, and comparatively low cost as
compared with that of other plating.
[0016]
The tin-plated steel sheet to be used in the present
35 invention may be a conventional electroplated tin plate,
and may be treated by iron-tin alloying (reflow
treatment) after the tin plating, as desired. The amount
- 14 -
of tin plating may preferably be in the range of 0.5 to
12.0 g/m2 from the viewpoint of suppression of iron
dissolution from dented parts of the film laminate or
coating. If the amount of tin plating is less than 0.5
5 g/m2, the amount of iron dissolution after denting becomes
greater and the corrosion resistance falls, so this may
not be preferred. On the other hand, even if the amount
of tin plating exceeds 12.0 g/m2, the functions are not
particularly obstructed, but in the production process,
10 the tin easily sticks to and builds up on the rolls etc.,
and causes dents or the plating costs swells more than
necessary. Thus, this may not be preferred.
[001°71
15 The environmentally friendly steel sheet for a
container material according to the present invention may
not necessarily be a plated steel sheet. However, in
order to secure a sufficient corrosion resistance with
respect to contents to be contained in a container
20 material, the surface of the side of the container
material to be in contact with the contents after the can
manufacturing may preferably be plated with tin or an
iron-tin alloy. When the tin oxide layer present on the
surface of a tin-plated steel sheet is too thick, even in
25 the case of the formation of a zirconium compoundcontaining
coating film on the tin oxide layer, the tin
oxide layer so fragile that the coating may be peeled off
together with the tin oxide layer, to thereby deteriorate
the coating adhesion. Accordingly, it is preferred to
30 remove the tin oxide layer, immediately before the
cathodic electrolytic coating treatment.
[0018]
Fig. 1 is a graph showing the results of evaluating
the coating adhesion in terms of T-peel strength
35 appearing hereinafter by using a zirconium compoundcontaining
coating film having an amount converted to
zirconium of 2to 4 mg/m2 which has been formed by using a
- 15
zirconium sulfate electrolytic treatment on a tin-plated
steel sheet (tin coating amount on one side: 2.8 g/m2)
which has been subjected to a tin oxide removal treatment
while changing the immersion time in sulfuric acid.
5 [0019]
As can be seen from Fig. 1, when the amount of tin
oxide on the tin plating is in the range of 0 mC/cm2 to
3.5 mC/cm2 measured by the electrolytic stripping method,
the coating adhesion is stable at a T-peel strength of 60
10 or more. On the other hand, when the amount of tin oxide
exceeds 3.5 mC/cm2, the coating adhesion is abruptly
decreased. It is presumed that an increase in the amount
of tin oxide reduces the wettability of the surface, and
accordingly the zirconium compound-containing coating
15 film is not deposited uniformly during the electrolytic
coating treatment of zirconium sulfate, to thereby
decrease the strength of coating adhesion. When the
amount of tin oxide on the tin plating exceeds about 3.5
mC/cm2, the tin plating comes to be entirely covered with
20 the tin oxide layer, and accordingly the tin oxide may
easily be peeled off from the fragile tin oxide layer, at
the time of the forming thereof or under the application
of an impact. It is presumed that such a phenomenon
causes a decrease in the coating adhesion.
25 [0020]
For the above reasons, in order to stabilize the
attachment of a zirconium compound on the tin-plated
layer or the iron-tin alloy layer, it is preferred to
remove the tin oxide layer of the tin-plated steel sheet
30 so as to provide a level thereof of 3.5 mC/cm2 or less
measured by the electrolytic stripping method.
[0021]
From the viewpoint of improvement in the adhesion of
the film or coating, it is preferred that no tin oxide
35 layer is present at all. However, even if the tin oxide
layer is completely removed, the tin will be oxidized at
the uppermost surface, provided that there is even a
- 16 -
little oxygen present. Therefore, the film lamination or
coating of the tin plated surface in a state where no tin
oxide is present at all, is difficult by ordinary
facilities. Even if this could be realized, the
5 manufacturing costs would swell, so this may not be
preferred.
[0022]
If the tin oxide layer on the tin plating is removed
to 0.01 mC/cm2, an equivalent adhesion may be obtained as
10 the state thereof with substantially no tin oxide layer,
so the thickness of the tin oxide layer may preferably be
in the range from 0.01 mC/cm2 to 3.5 mC/cm2. If the
manufacturing costs is not considered, the most
preferable lower limit of the thickness of the tin oxide
15 layer is 0 (mC/cm2). The more preferable upper limit of
the thickness of the tin oxide layer may be 3.0 (mC/cm2)
(mC/cm2)
[0023]
Herein, the electric stripping method refers to a
20 method of applying the principle of constant current
coulometry for constant current electrolysis of a test
piece, wherein the change in potential of the test piece
accompanying electric stripping is recorded by using a
pen recorder, and the amount of electricity, (that is,
25 the amount of deposition of surface tin and the oxide
film) is measured from the electrolysis time-potential
curve.
10024]
As the method of removing the tin oxide layer which
30 has been formed on a tin-plating layer or iron-tin alloy
layer, it is most desirable to use a treatment by using
cathodic electrolysis in a sodium carbonate or sodium
hydrogen carbonate solution, since the tin oxide layer
may reliably be removed in a short time and almost no tin
35 dissolving-out is observed.
[0025]
When a tin-plated steel sheet is subjected to
cathodic electrolysis in an aqueous solution of sodium
carbonate or sodium hydrogen carbonate, the concentration
range of sodium carbonate or sodium hydrogen carbonate
may preferably be 1 mass % to 5 mass When the
5 concentration of the aqueous solution of sodium carbonate
or sodium hydrogen carbonate is less than 1 mass %, the
tin oxide layer may sometimes remain and accordingly this
may not be preferred. When the concentration of the
aqueous solution of sodium carbonate or sodium hydrogen
10 carbonate exceeds 5 mass %, sufficient washing with water
may be required after the treatment, otherwise the sodium
carbonate or sodium hydrogen carbonate may sometimes
remain, and accordingly this may not be preferred. When
the solution temperature during the electrolytic coating
15 treatment is low, the solubility of sodium carbonate or
sodium hydrogen carbonate becomes lower, and accordingly
the solution temperature may preferably be 5°C or more.
The upper limit of the solution temperature is not
particularly limited, and any temperature can be used as
20 long as it does not make the handling thereof dangerous.
[00261
When the current density during the cathodic
electrolysis is too low, the removal of the tin oxide
layer may become uneven, and accordingly the treatment
25 with 1 A/dm2 or more of the current density may be
preferred. The upper limit of the current density is not
be particularly limited, but when the current density is
too high, the removal efficiency of tin oxide does not
considerably be changed, despite the presence of vigorous
30 generation of hydrogen, and accordingly about 10 A/dm2 or
less may be preferred.
(00271
Further, it is also preferred to use a method of
removing the tin oxide layer which has been formed on a
35 tin-plated layer or the iron-tin alloy layer by the
immersion thereof in an aqueous sulfuric acid solution.
The concentration of the aqueous sulfuric acid solution
18 -
may preferably be 0.5 mass % or more and 5 mass %.or
less. When the concentration of the aqueous sulfuric
acid solution is less than 0.5 mass %, the tin oxide
layer cannot be fully removed and accordingly this may
5 not be preferred. The higher the concentration of the
aqueous sulfuric acid solution, the easier the tin oxide
is removed. However, a higher concentration thereof may
cause rough skin or the residual sulfuric acid so as to
reduce the coating adhesion, and accordingly the upper
10 limit of the concentration of the aqueous sulfuric acid
solution may preferably be 5 mass % or less. The
temperature of the aqueous sulfuric acid solution may
preferably be in the range of 10°C or more and 80°C or
less. When the liquid temperature of the aqueous
15 sulfuric acid solution is less than 10°C, the rate of
removing tin oxide becomes very low, and tin oxide may
sometimes remain, and accordingly, this may not be
preferred. On the other hand, when the temperature of
the aqueous sulfuric acid solution exceeds 80°C, the rate
20 of removing tin oxide becomes significantly high, and the
tin-plated surface may excessively be etched, so as to
provide uneven gloss, and accordingly, this may not be
preferred.
[0028]
25
In the cathodic electrolytic coating treatment
according to the present invention, a tin-plated steel
sheet or an iron-tin alloy plated steel sheet is
subjected to a cathodic electrolytic coating treatment in
30 an aqueous solution of an alkali metal sulfate which does
not contain a chromium compound, fluorine or nitrate
nitrogen, but contains a zirconium compound, wherein the
zirconium concentration in the cathodic electrolytic
coating treatment solution is 10 mg/L or more and 2000
35 mg/L or less, the electric conductivity of the treatment
solution is 0.2 S/m or more and 6.0 S/m or less, and the
- 19 -
pH of the treatment solution is 1.5 or more and 2.5 or
less.
[0029]
The purpose of using a zirconium compound as a
5 primer agent is to coat the surface of a steel sheet with
a zirconium oxide hydrate, so as to form hydrogen bonding
between the zirconium oxide hydrate and hydroxy groups
contained in the resin coating layer, similarly as in the
case of the chromate treatment, to thereby enhance the
10 adhesion with the resin coating film.
[0030]
For the purpose of obtaining an effect similar to
that of a zirconium compound, the present inventors have
examined various metal-based oxides for suitability as
15 the cathodic electrolytic coating treatment agent. As a
result, the present inventors have found that the
cathodic electrolytic coating treatment with a zirconium
compound provided the best adhesion with a resin coating
film (particular, in view of the secondary adhesion after
20 retort treatment). As a metal salt not containing a
chromium compound, fluorine or nitrate nitrogen to be
used in the process of depositing:a zirconium compound by
using a cathodic electrolytic coating treatment, it is
possible to use a carbonate, a sulfate, a halogenated
25 salts Among these, zirconium sulfate may be m°st
preferred, since its aqueous solution is stable, and
industrially easily available.
10031]
As the process of forming a zirconium compound into
30 a cathodic electrolytic coating treatment layer, it is
general to use a cathodic electrolytic coating treatment
in an aqueous solution of zirconium fluoride. Since a
fluoride-containing bath has a heavy load to the waste
treatment to be used therefor, Patent Document 3 as
35 mentioned above proposes the use of zirconium sulfate in
stead of a zirconium fluoride compound, in the cathodic
electrolytic coating treatment.
- 20 -
However, the method of forming a coating film by the
cathodic electrolytic coating treatment of a sulfate
compound has a characteristic that the deposition of a
zirconium oxide hydrate is markedly changed depending on
5 the current density, and accordingly it is difficult to
keep the coating amount of a zirconium oxide hydrate in
an appropriate range. When the coating amount of the
coating film of a zirconium oxide hydrate is changed, it
causes unevenness in the coating adhesion and film
10 adhesion, and accordingly this may not be preferred.
Further, the aqueous zirconium sulfate solution has
a problem in storage stability, that is, when a high
concentration zirconium solution is stored at a high
temperature (40°C or higher) for a long time, precipitates
15 of a zirconium oxide hydrate is liable to be formed.
[0032]
In view of these problems, in the present invention,
a zirconium compound is added to an aqueous solution of
an alkali metal sulfate, so that the deposition behavior
20 of the zirconium oxide hydrate is stabilized with respect
to the current density during the cathodic electrolytic
coating treatment, as well as the storage stability of
the solution is enhanced. As a result, the unevenness in
the coating amount of a zirconium oxide hydrate can be
25 reduced or obviated, even when the operation condition
slightly is changed to a certain extent, and accordingly
a drastic enhancement in the stability of the solution is
attained during a long-time use.
[0033]
30 First, a mechanism of forming a zirconium oxide
hydrate coating by cathodic electrolytic coating
treatment of a tin-plated steel sheet in an aqueous
solution of alkali metal sulfate containing a zirconium
compound will be explained (hereinafter, there will be
35 described an embodiment using "an aqueous solution of
zirconium sulfate to which sodium sulfate has been added"
as an example).
- 21 -
It is presumed that zirconium is be present as ZrO2
in an aqueous sodium sulfate solution, It is also
presumed that ZrO2+ is stable at a low pH region, but the
stability of ZrO2 becomes lower as pH becomes higher, so
5 that it is liable to be deposited as a hydrated oxide.
When sodium sulfate is subjected to a cathodic
electrolytic coating treatment, hydrogen gas is generated
at the interface with the solution at the tin-plated
steel sheet side of the cathode, and as a result, the
10 hydroxide ion concentration in the vicinity of the
interface may become higher (i.e., pH id increased). It
is presumed that, when the pH of the interface becomes
higher, ZrO2 begins to be deposited as a hydrated oxide,
and a coating film of zirconium oxide hydrate is formed
15 on the tin-plated steel sheet.
[00341
Then, the effect of adding a zirconium compound to
an aqueous sodium sulfate solution will be explained.
As described above, when a tin-plated steel sheet is
20 subjected to a cathodic electrolytic treatment in an
aqueous zirconium sulfate solution, the interface pH is
increased so as to form a zirconium hydroxide coating
film. Since the diffusion rate of ions in an aqueous
solution is slow, it is presumed that a significantly
25 thick high--pH layer is formed in the vicinity o the
interface, and when the interface pH reaches a condition
for the deposition of zirconium hydroxide, a zirconium
oxide hydrate coating film is formed abruptly.
Accordingly, in a cathodic electrolysis solution
30 comprising a zirconium sulfate alone, it is expected that
the coating amount of the zirconium hydroxide coating
film may be changed markedly depending on variation in
current density or pH.
As a first effect of using an aqueous solution of an
35 alkali metal sulfate as a base solution, the aqueous
solution of the alkali metal sulfate acts as an
electrolyte, and it reduces the electric resistance of
- 22 --
the solution. This has an effect of reducing the burden
or load to the rectifier.
As a second effect, the alkali metal ion neutralizes
the hydroxide ions which have been formed at the
5 interface of the tin-plated steel sheet and the cathodic
electrolytic solution by the cathodic electrolytic
treatment, so that a high pH layer having an appropriate
thickness can be formed on the interface, to thereby
provide an effect of suppressing the variation in the
10 coating amount of the zirconium hydroxide coating film
due to the variation in the current density variation or
in the pH (specifically, in a case where ions such as Na+
and K+ are present in large quantities near the
electrode).
15 [0035]
Then, there is described the effect on the coating
amount in the cathodic electrolytic treatment and the
current density during the cathodic electrolytic
treatment, and on the pH of the solution, in a case where
20 an aqueous zirconium sulfate solution alone is subjected
to cathodic electrolytic treatment of the prior art, and
in a case where an aqueous solution of an alkali metal
sulfate containing a zirconium compound according to the
present invention is subjected to cathodic electrolytic
25 treatment.
[0036]
Fig. 2 is a graph showing a relationship between the
current density during the cathodic electrolytic coating
treatment and the zirconium compound coating amount which
30 has been deposited to the steel sheet, when a tin-plated
steel sheet (amount of tin-plating: 2.8 g/m2) which has
been subjected to a tin oxide removal treatment, is
subjected to a cathodic electrolytic coating treatment,
by using an aqueous solution, wherein zirconium sulfate
35 has been added to a 402 mass %-aqueous sodium sulfate
solution so as to provide a concentration converted to
zirconium of 400 mg/L, and the pH thereof has been
- 23 -
regulated to 1.9 by the addition of sulfuric thereto.
As can be seen from Fig. 2, in a case where the
cathodic electrolytic coating treatment is performed in a
treatment solution comprising zirconium sulfate alone,
5 the increasing rate of the coating amount of the
zirconium compound-containing coating film is small in
the low current density region, but the increasing rate
of the coating amount of the zirconium compoundcontaining
coating film tends to be increased abruptly at
10 a specific current density. In contrast thereto, in a
case where a sodium sulfate treatment solution to which
zirconium compound has been added is used, the variation
in the coating amount of the zirconium compound with
respect to an increase in the current density is small
15 (i.e., the degree of increase in the coating amount of
the zirconium compound-containing coating film with
respect to the increase in the current density is
moderate), and accordingly, this operational stability is
high and preferable.
20 The alkali metal sulfate may appropriately be
selected from sodium sulfate and potassium sulfate, since
both of them give a similar effect.
[00371
As describe above, in a chromium-free treatment
25 process according to the present invention wherein a
zirconium compound is added to an aqueous solution of an
alkali metal sulfate such as sodium sulfate and potassium
sulfate, even if the current density condition may be
changed to a certain extent, the variation in the coating
30 amount of a zirconium compound-containing coating film is
small, and a stable operation can be realized.
[00301
Fig, 3 is a graph showing a relationship between the
pH of a solution and the amount of the zirconium
35 compound-containing coating film on a tin-plated steel
sheet, when the tin-plated steel sheet is subjected to a
cathodic electrolytic coating treatment at a current
- 24 -
density of 5 A/dm2 for 5 seconds, by using an aqueous
zirconium sulfate solution wherein the pH has been
lowered by adding sulfuric acid to an aqueous zirconium
sulfate solution of pH 1.9, and an aqueous sodium sulfate
5 solution containing a zirconium compound wherein pH is
raised by mixing sodium sulfate with an aqueous zirconium
sulfate solution of pH 1.6.
As can be seen from Fig. 3, in a case where the
cathodic electrolytic coating treatment is performed in a
10 treatment solution containing zirconium sulfate alone, a
change in pH leads to extreme variation in the coating
amount of the zirconium compound-containing coating film.
On the other hand, in the case of an aqueous sodium
sulfate solution containing a zirconium compound, even
15 when pH is changed, the variation in the coating amount
of the zirconium compound-containing coating film is
small. Accordingly, in this case, even if pH is lowered
by a continuous cathodic electrolytic coating treatment,
the coating amount of the zirconium compound-containing
20 coating film does not show an abrupt decrease. That is,
the coating amount is stable.
(Ob397
As described above, as compared to an aqueous
zirconium sulfate solution, in the case of a solution
25 wherein a zirconium compound is added to an aqueous
solution of an alkali metal sulfate such as sodium
sulfate and potassium sulfate, the variation in the
coating amount of the zirconium compound-containing
coating film is small with respect to a change in the
30 electrolytic condition, and accordingly it is easy to
keep the coating amount of the zirconium compoundcontaining
coating film in an appropriate range, and
stable production can be attained.
[00401
35 With regard to the concentration of the alkali metal
sulfate of an aqueous solution of the alkali metal
sulfate containing a zirconium compound, the alkali metal
25 -
sulfate may be deposited in an environment of 5°C or less,
and accordingly the upper limit of the concentration of
the alkali metal sulfate may preferably be 8.0 mass % or
less.
5 [0041]
With regard to the lower limit of concentration of
the alkali metal sulfate in an aqueous solution of the
alkali metal sulfate containing a zirconium compound, the
alkali metal sulfate may not be required, as long as the
10 optimum range of the electric conductivity and the
optimum pH of the solution appearing hereinafter are to
be satisfied. However, with the aqueous zirconium
sulfate solution alone, as described hereinabove, not
only the coating amount of the zirconium compound-
15 containing coating film may become unstable with respect
to variation in the electrolysis condition, but also the
presence of the alkali metal ion in an aqueous solution
can enhance the stability of the solution, and
accordingly, the alkali metal sulfate is essential.
20 Incidentally, when the lower limit of the zirconium
concentration in an aqueous zirconium sulfate solution is
10mg/L and the upper limit of pH is 2.5, 0.1 mass % of
the alkali metal sulfate may be required, and accordingly
the lower limit range of the concentration of the alkali
25 metal sulfate may be 0.1 mass %.
[0042]
Then, an appropriate range of the coating amount of
She zirconium compound-containing coating film will be
explained.
30 Since the coating material adhesion of a tin-plated
steel sheet to which a zirconium compound-containing
coating film has been applied by a cathodic electrolytic
coating treatment may be changed depending on the coating
amount of the zirconium compound-containing coating film,
35 it is important to clarify the appropriate range of the
coating amount of the zirconium compound-containing
coating film.
26 --
Fig. 4 is a graph showing a relationship between the
film coating amount converted to zirconium and the
coating material adhesion after coating of a tin-plated
steel sheet which has been subjected to a cathodic
5 electrolytic coating treatment in an aqueous zirconium
sulfate solution. Herein, the coating material adhesion
is evaluated by using the T-peel strength appearing
hereinafter.
As can be seen from Fig. 4, the T-peel strength is
10 stable at 60 N/10 mm or more in the range of a film
coating amount converted to zirconium of Oel mg/mz to 20
mg/mz e However, in the zirconium compound-containing
coating film amount outside of this range, the T-peel
strength is not stable and a sufficient forming adhesion
15 after the coating cannot be obtained.
[00431
Then, the concentration of zirconium to be contained
in the cathodic electrolytic coating treatment solution
according to the present invention will be explained.
20 As shown in Fig. 5, in a case where the
concentration of zirconium contained in the cathodic
electrolytic coating treatment solution according to the
present invention is less than 10 mg/L, for example at a
low current density such as 2 A/dmz, the coating amount of
25 the zirconium compound-containing coating film after the
cathodic electrolytic coating treatment may become lower
than the lower limit as describe above of Oel mg/mz of the
film coating amount converted to zirconium, and
accordingly this may not be preferred.
30 Therefore, the zirconium concentration in an aqueous
solution of an alkali metal sulfate containing a
zirconium compound may preferably be 10 mg/L or more,
[00441
On the other hand, when the concentration of
35 zirconium contained in the cathodic electrolytic coating
treatment solution exceeds 2000 mg/L, the storage
stability of the solution may be reduced, and after a
- 27 -
long-time storage, the sludge of zirconium oxide hydrate
may be deposited as shown in Fig. 6, and this may not be
preferred.
Further, when the concentration of zirconium
5 contained in the cathodic electrolytic coating treatment
solution exceeds 2000 mg/L, the zirconium compoundcontaining
coating film on the steel sheet surface tends
to be uneven, and sludge tends to be formed during the
electrolytic treatment, and accordingly this may not be
10 preferred. When the concentration of an aqueous
zirconium sulfate solution is high, the amount of the
solution to be taken out during a continuous threading
operation becomes large, and this is not economical.
For the above reasons, the concentration of
15 zirconium contained in the cathodic electrolytic coating
treatment solution according to the present invention may
preferably be 10 mg/L or more and 2000 mg/L or less.
[0045]
The electric conductivity of the cathodic
20 electrolytic coating treatment solution according to the
present invention may be changed depending on the
concentration of an aqueous solution of an alkali metal
sulfate, the amount of a zirconium compound and pH, but
an appropriate range of the electric conductivity is 0.2
25 S/m or more and 6.0 S/m or less. Hereinbelow, the
reasons therefor will be explained in Fig. 7 and Fig. 8.
[00461
- Fig. 7 is a graph showing a relationship between the
electric conductivity of a solution and the rectifier
30 voltage, when the cathodic electrolytic coating treatment
of a tin-plated steel sheet is performed by the changing
current density from 1 A/dm2 to 10 A/dm2 by using a
solution having a zirconium concentration of 10 mg/L and
pH of 1.9, wherein the electric conductivity is changed
35 by changing the concentration of an aqueous solution of
sodium sulfate. As can be seen from Fig. 7, when the
electric conductivity of the solution becomes lower than
- 28 -
0.2 S/m, the voltage of the rectifier comes to exceed 25
V, even if the current density is 1 A/dmZ, to thereby
increase the load on the rectifier.
In view of the use of the present chromium plating
5 equipment as it is without changing the electrode length
or the electrolytic treatment path number, the voltage
during the operation should be about 25 V at the highest,
since the upper limit of voltage of the actual rectifier
is generally about 25 V.
10 On the other hand, if the predetermined value of the
current density is lowered, the voltage can be lowered.
However, an excessively low current density can make the
depositing property of a zirconium compound unstable, and
this may not be preferred, but about 1 A/dmZ at the lowest
15 may be preferred. Thus, as can be suggested from Fig. 7,
the lower limit of the electric conductivity of an
electrolytic solution may preferably be 0.2 S/m or more.
[00471
An optimum current density when a tin-plated steel
20 sheet or an iron-tin alloy-plated steel sheet is
subjected to a cathodic electrolytic coating treatment by
using the cathodic electrolytic coating treatment
solution according to the present invention may
appropriately be selected based on the coating amount of
25 a zirconium compound-containing coating film which is to
be deposited on the tin-plated steel sheet or the irontin
alloy-plated steel sheet. However, if the current
density is too high, the hydrogen generation from the
steel sheet side as a cathode side becomes vigorous, and
30 accordingly the deposited zirconium compound may be peel
off by the thus generated hydrogen gas, whereby uneven
coating is liable to be caused. Accordingly, the
electrolytic treatment at about 30 A/dmZ or less may be
preferred.
35 [0048]
Then, the upper limit of the electric conductivity
of the cathodic electrolytic coating treatment solution
- 29 -
according to the present invention will be explained.
When the concentration of an aqueous solution of an
alkali metal sulfate in the cathodic electrolytic coating
treatment solution according to the present invention is
5 increasingly raised, the load to the rectifier becomes
smaller, and accordingly the current density can be
raised. However, if the electric conductivity becomes
too high, the coating amount of zirconium compound--
containing coating film tends to be decreased, to thereby
10 cause an uneven outer appearance, which may not be
preferred.
[0049]
Fig. 8 is a graph showing the electric conductivity
of the solution, and the coating amount converted to
15 zirconium of a zirconium compound, when a tin--plated
steel sheet or a iron-tin alloy-plated steel sheet is
subjected to a cathodic electrolytic coating treatment at
a current density of 15 A/dm2 using a solution with a
zirconium concentration of 50 mg/L and pH of 1.7, wherein
20 the electric conductivity is changed by changing the
concentration of an alkali metal sulfate in an aqueous
sodium sulfate solution containing a zirconium compound,
or an aqueous potassium sulfate solution containing a
zirconium compound.
25 [0050]
As can be seen from Fig. 8, the coating amount of
the zirconium compound-containing coating film tends to
be decreased, as the electric conductivity of the
solution comes to exceed about 6.0 S/m.
30 In the reaction at the cathode side where no alkali
metal ions are present, hydrogen ions first receive
electrons to become hydrogen gas to be released, and the
hydroxide ion concentration at the interface is increased
(i.e., pH is increased), and as a result, zirconium oxide
35 ions (ZrO2+) are deposited as zirconium oxide hydrate. In
contrast thereto, it is presumed, when alkali metal ions
are present, Na ions also participate in the transfer of
- 30 -
electrons at the cathode interface (while the deposited
metal Na is immediately dissolved and dissociated), and
accordingly as compared to a case where no alkali metals
are added, the concentration of hydroxide ions which have
5 been formed at the interface becomes lower, whereby the
deposition of zirconium oxide hydrates is inhibited.
Accordingly, if the electric conductivity is
excessively increased by adding the alkali metal ions,
the interface pH at the cathode side is less liable to be
10 increased, and the deposition of zirconium hydroxides
becomes more difficult. Accordingly, the electric
conductivity of the solution may preferably be 6.0 S/m or
less.
[0051)
15 Next, the optimum pH range of the cathodic
electrolytic coating treatment solution according to the
present invention will be explained.
With regard to the lower limit of pH of the cathodic
electrolytic coating treatment solution according to the
20 present invention, when the pH becomes lower, as shown in
Fig. 9, the coating amount of the zirconium compoundcontaining
coating film tends to be decreased, and at
less than pH 1.5, the film coating amount converted to
zirconium does not reach the lower limit target of 0,1
25 mg/m2, and accordingly this may not be preferred.
It is presumed that the mechanism of the deposition
of the zirconium compound-containing coating film is the
deposition of zirconium oxide hydrate due to an increase
in the concentration of hydroxide ions (i.e., an increase
30 in pH) at the interface caused by the hydrogen gas
generation during the cathodic electrolytic treatment,
and when the pH of the cathodic electrolytic coating
treatment solution is low, the hydroxide ion
concentration at the cathode cannot be increased, and as
35 a result, the formation of the coating film of the
zirconium oxide hydrate becomes difficult.
When the amount of the zirconium oxide hydrate
- 31 -
deposited is small, the lower limit (a film coating
amount converted to zirconium of 0.1 mg/m2 or more) of the
amount of the zirconium compound-containing coating film
capable of giving the favorable adhesion of the coating
5 material cannot be obtained, and this may not be
preferred.
Accordingly, the lower limit of pH of the cathodic
electrolytic solution according to the present invention
may preferably be 1.5 or more.
10 [0052]
Then, the upper limit of pH of the cathodic
electrolytic coating treatment solution according to the
present invention will be explained.
Fig. 10 is graph showing the storage stability
15 (which has been evaluated from the presence or absence of
precipitate generation in a solution which has been
allowed to stand at 40°C for 2 weeks) of an aqueous
solution of sodium sulfate containing a zirconium
compound, and an aqueous solution comprising zirconium
20 sulfate alone. As can be seen from Fig. 10, in the
aqueous solution comprising zirconium sulfate alone, the
storage stability of the solution is decreased when pH
exceeds 2.1.
In an aqueous zirconium sulfate solution, zirconium
25 is present in the form of ZrO2,+Accordingly, i1t is
considered that as the pH becomes higher, ZrO2 tends to
be deposited in the form of a hydrated oxide, and when an
aqueous zirconium sulfate solution having a high pH is
stored for a long time or at a high temperature, ZrO2
30 ions which have been dissolved in the solution are
deposited as a zirconium oxide hydrate, and the resultant
deposition becomes a white precipitate.
[0053]
On the other hand, in the case of an aqueous sodium
35 sulfate solution containing a zirconium compound as shown
in Fig. 10, it is found that the upper limit of the
stable pH region of the solution is extended to pH 2.5.
_, 32 -
This is probably because, in the aqueous solution of an
alkali metal sulfate, hydroxide ions are coordinated with
the dissociated alkali metal. ions, and as a result, the
number of hydroxide ions to be coordinated with ZrO2
5 become smaller, to thereby enhance the stability of ZrO2,+
In the case of an aqueous solution of sodium sulfate
containing a zirconium compound, a white precipitate may
be formed at a pH of 2.5 as the upper limit, and
accordingly the pH may preferably be 2.5 or less.
10 Further, when a continuous electrolytic treatment
operation is performed by using a high-pH solution,
sludge is liable to be formed in a large amount, and
accordingly also in view of the operability and product
quality, the pH may preferably be 2.5 or less.
15 [0054]
As as alkali metal sulfate to be used in the
cathodic electrolytic coating treatment solution
according to the present invention, sodium sulfate and
potassium sulfate may be preferred in view of easy
20 availability and easy handling.
[0055]
Fig. 11 is a graph showing a relationship between
the sodium sulfate concentration (mass % ) and the
electric conductivity of an aqueous solutions of sodium
25 sulfate containing a zirconium compound (the zirconium
concentration: 10 mg/L). In this case, the pH of the
solution has been regulated to 1.5 and 2.5 by adding
sulfuric acid.
Fig. 12 is a graph showing a relationship between
30 the sodium sulfate concentration (mass % ) and the
electric conductivity of an aqueous solutions of sodium
sulfate containing a zirconium compound (the zirconium
concentration: 2000 mg/L). In this case, the pH of the
solution has been regulated to 1.5 and 2.5 by adding
35 sulfuric acid.
[0056]
As can be seen from Fig. 11 and Fig. 12, the
33 -
electric conductivity of the cathodic electrolytic
coating treatment solution according to the present
invention may be changed depending on the concentration
of the zirconium compound, the concentration of the
5 alkali metal sulfate, and pH. Accordingly, after the
determination of the concentration of a zirconium
compound, it may be preferred to regulate the pH and the
electric conductivity to be in an appropriate range by
adding, as appropriate, a suitable amount of the alkali
10 metal sulfate and concentrated sulfuric acid.
[0057]
With regard to the temperature of a treatment
solution during the cathodic electrolytic coating
treatment according to the present invention, a range of
15 5°C to 50°C provides a high deposition efficiency of a
zirconium compound and a small variation in the
concentration due to evaporation, and accordingly this
range may be preferred.
When the temperature of the solution becomes high,
20 the rate of supplying hydrogen ions to the cathode
interface is increased, and the zirconium compound is
less liable to be deposited. Accordingly, in order to
obtain an appropriate zirconium coating amount, the
current density should be enhanced, and as a result, the
25 load to the rectifier becomes excessive. Accordingly,
the temperature of the solution may preferably be 50°C or
less.
Further, if the temperature of the solution is high,
the stability of the solution is decreased, and zirconium
30 oxide hydrate is liable to be deposited. For this reason
as well, the upper limit of the temperature of the
solution may preferably be 50°C or less.
[0058]
With regard to the lower limit of the temperature of
35 the solution during the cathodic electrolytic coating
treatment, when the concentration of the alkali metal
34 -
sulfate is high, the alkali metal sulfate may be
deposited, if the temperature is below 5°C. Therefore,
the lower limit of the temperature of the solution may
preferably be 5°C or more.
5 [0059]
In the cathodic electrolytic coating treatment
according to the present invention, after the treatment,
it is preferred to conduct washing with water or washing
with warm water. When the cathodic electrolytic coating
10 treatment solution according to the present invention is
subjected to an electrolytic treatment, sulfate ions
(SO42-) may remain in the zirconium compound-containing
coating film, and the excess sulfate ions remaining in
the coating film may cause a color change so that a stain
15 on the surface may be caused and the adhesion after
coating may be decreased. Accordingly, such residual
ions may not be preferred.
[0060]
After the cathodic electrolytic coating treatment
20 with the cathodic electrolytic coating treatment solution
according to the present invention, it is sufficient to
conduct washing with water or washing with warm water, in
an extent such that the washing operation may not be a
heavy burden. The amount of sulfate ions (S042-)
25 remaining in the zirconium compound-containing coating
film may preferably be controlled to be within a range
(0.2 mg/m2 or more and 7 mg/m2 or less) which is almost
equal to that of the remaining sulfate ions after the
chromate treatment.
30 [0061]
After the cathodic electrolytic coating treatment,
it is preferred to conduct drying so as to evaporate the
moisture. The drying operation may conducted by natural
drying or hot-air drying. When the coating amount of the
35 zirconium compound is large, much moisture may remain in
the coating film. Accordingly, in this case, hot-air
drying may be more preferred.
- 35 -
The steel sheet for a container material according
to the present invention as described above may
preferably be used for the production of a laminated
5 steel sheet for a container material. The structure of
such a laminated steel sheet for a container material
using a steel sheet for a container material according to
the present invention is not particularly limited. For
example, such a laminated steel sheet for a container
10 material may preferably comprise, at least, a steel sheet
for a container material as describe hereinabove, and a
laminate film disposed thereon.