Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Patent
1993-06-17
1995-04-11
Szekely, Peter
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
524274, 524447, 524486, 524495, 524496, 524505, 524575, 525 71, 428457, 428461, 428462, 428521, C08K 542, C08K 501, C08K 334, C08L 9304
Patent
active
054058945
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to compositions and their use as coating materials particularly for the undercoating of motor vehicles to prevent chipping and corrosion.
Automobile undercoatings typically consist of several layers on a metal, usually phosphorized metal. First the phosphorized metal is painted, it is subsequently coated with a layer of a polyvinyl chloride plastisol, generally applied as a dispersion, which is fused to provide a rendered chip resistant coating. Frequently the plastisol is filled with a substantial amount of filler, typically calcium carbonate. Once the polyvinyl chloride layer is applied and fused it may itself be coated with a layer of wax to inhibit decomposition of the polyvinyl chloride and consequential corrosion. There may also be incorporated an anticorrosion material which may include a thixotropic calcium sulphonate, but the-sulphonate cannot be incorporated into the polyvinyl chloride because of the incompatibility of the plasticizer of the plastisol with large quantities of oil, which are normally present in the calcium sulphonate materials.
These coating systems are complex and furthermore there is a desire to replace the polyvinyl chloride to avoid toxicological problems in the disposal of vehicles by combustion. The polyvinyl chloride layer furthermore provides very limited anticorrosion properties and its flexibility under changing temperature and stress conditions can be unsatisfactory.
Various alternative coating compositions have been tried but have not proved satisfactory since they do not satisfy one or more of the requirements, particularly the ability to be applied as a solution or dispersion which can give a coating with sufficient adhesion to metal, which does not sag and. which has sufficient temperature and stress endurance. It is also desirable to have a coating that can be applied at a high solids level by the preferred spraying techniques at ambient temperature so reducing the amount of solvent used and facilitating its removal. Furthermore, it would be highly desirable to have a single treatment which provides both anticorrosion and chip resistance to the underside of the vehicle. Still further, it would be of advantage if the coating could be disposed of, when the vehicle is scrapped, without harming the environment.
Numerous coating compositions have been proposed, many of which have been used commercially, for the coating of ferrous and non-ferrous metals susceptible to rust or corrosion, to prevent or inhibit such rust or corrosion. As has long been known, rust or corrosion is caused by environmental conditions, such as contact of the metal surfaces with water and oxygen; by air, particularly moist air and by various chemicals or other materials which come into contact with the metal surfaces.
While, in most cases, ferrous metals such as iron and steels represent the areas where rust and corrosion problems are particularly encountered, various non-ferrous metals, for instance, aluminium, are also subject to corrosion.
The use of corrosion-inhibiting coating compositions, which contain thixotropic, or grease-like or gel-like thixotropic, alkaline earth metal organic sulphonates complexed with alkaline earth metal carbonates, with or without admixture with polymers, resins or waxes, in a carrier or diluent of nonvolatile or volatile (or mixtures of nonvolatile and volatile) hydrocarbons and/or other liquid solvents, is disclosed in U.S. Pat. Nos. 3,453,124; 3,492,231; 3,565,672; 3,565,843; 3,661,662; 3,746,643; and 3,816,310; and United Kingdom Patent No. 1,249,144 and various patents referred to in the specifications of such patents. Various of such corrosion-inhibiting compositions are proposed for a variety of purposes, some including automobile and truck body undercoatings, and others for use in other environments.
There are numerous other proposals for compositions for vehicle underbody coatings. In JP-A-1-247439 a composition comprising a styrene-olefin elastomer, a fat-based plasticizer and a hydrocarbon-based plasticizer is described, o
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patent: 4729791 (1988-03-01), Laura et al.
patent: 5283276 (1994-02-01), Best et al.
Exxon Chemical Patents Inc.
Szekely Peter
White Vivienne T.
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