Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Physical dimension specified
Patent
1996-03-11
2000-01-18
Zimmerman, John J.
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Physical dimension specified
428457, 428461, 428469, 427256, 427409, B32B 1504, B32B 1508, B05D 500
Patent
active
060156139
DESCRIPTION:
BRIEF SUMMARY
This invention provides corrosion resistant metal laminates and methods of providing such laminates employing coatings of a mixture of inherently conducting polymer in a non-conducting matrix.
BACKGROUND OF THE INVENTION
Corrosion is a problem associated with virtually all metal objects that are exposed to an oxidizing environment. The effects of corrosion are particularly noticeable in automobiles, ships, aircraft, heavy machinery and bridges. Corrosion is a serious problem in the road construction industry, in various industrial processes and in medical devices. Metal corrosion is especially severe in harsh environmental conditions, e.g. exposure to acid, base or salts. Corrosion resistant coatings such as zinc, epoxy, tar, polymer and paint are typically applied as adhesive coatings on the exposed surfaces of a metal object providing a barrier to environmental attack. Although such coatings can comprise simply a polymeric composition, they commonly includes corrosion inhibiting heavy metal or toxic organic compounds to enhance corrosion resistance. Other diverse corrosion inhibiting compositions and materials are disclosed in U.S. Pat. Nos. 5,152,929, 4,818,777, 5,098,938, 5,021,489 and 5,183,842.
The application of a corrosion inhibiting coating onto a metal object is, however, not a complete solution to corrosion because most coatings are subject to cracks, chips, or scratches which expose the bare metal to the corrosive environment. Even the existence of pinhole discontinuities in a coating can be defeat the anticorrosion function of a coating. In this regard, the effects of corrosion at discrete locations as a result of a chip or a scratch can be particularly severe because the effects of the corrosive elements are concentrated at the point of exposure. Accordingly, conventional corrosion inhibiting compositions are not completely satisfactory in providing corrosion resistance to metal objects.
Intrinsically conducting polymers (ICP), organic polymers that have poly-conjugated .pi.-electron systems, have been proposed as potential corrosion inhibiting compositions for metals. Such polymers have not heretofore been considered suitable as protective coatings because of the intractable nature of ICP's. That is, the class of ICP's lack the necessary properties, such as cohesion, adhesion, processability and stability, to be acceptable-for use as a protective coating on a metal object. Others have attempted to improve the properties of ICP's by modifying them or blending them with other polymers. For instance, U.S. Pat. No. 5,109,070 discloses sulfonated ICP; European Patent Application No. 0 497 514 discloses blends of ICP's and thermoplastic polymers; U.S. Pat. No. 5,160,457 discloses compositions of doped polyaniline and one or more thermoplastic, solution processable or thermoset polymers; and U.S. Pat. No. 4,983,690 discloses blends of polyaniline and a bismaleimide thermoset. Despite the widespread investigation of ICP's and ICP containing systems, viable corrosion protection systems employing ICP's remain an unfulfilled promise.
SUMMARY OF THE INVENTION
The present invention is, therefore, directed to novel corrosion inhibiting compositions, corrosion inhibited metal surfaces coated with the corrosion inhibiting compositions and methods for providing corrosion resistance to metal objects. In one significant aspect, the present invention provides a non-metal, conductive coating composition comprising a blend of ICP in a non-conducting polymer matrix which is adapted for use in corrosion-resistant metal laminates. Such laminates provided by this invention comprise, in series, a metal layer, a non-metal conductive layer and a non-conducting layer. In another aspect, a two component corrosion inhibiting coating for a metal surface comprises an electrically conductive intermediate coating of a blend of ICP and a non-conducting adhesive matrix and a non-conducting top coat.
Among the many advantages of the coating compositions of this invention is the capability of providing corrosion protection e
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Hardiman Christopher John
Kinlen Patrick John
Silverman David Charles
LaVilla Michael
Zimmerman John J.
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