Formation Coating Application System Containing Hydrogel and Method of Using the Same

Abstract

The conversion coating applicator includes a first liner, a hydrogel attached to the first liner, and a second liner removably attached to the hydrogel. The hydrogel contains a trivalent chromium conversion coating solution containing a trivalent chromium compound, a zirconate compound, and a dye compound. The conversion coating solution is an aqueous solution.

Description

Technical Field

[0001] Cross - Reference to Related Applications

[0001] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 351,771, filed on June 13, 2022, entitled "Conversion Coating Application System Including Hydrogels and Methods of Using Same", the disclosure of which is hereby incorporated by reference in its entirety.

Background Art

[0002]

[0002] Conversion coatings are widely used to treat metal surfaces to improve corrosion resistance, increase the adhesion of subsequent coatings such as paints, form decorative finishes, or maintain electrical conductivity. A conversion coating is formed by applying a conversion coating solution to a metal. The conversion coating solution and the metal react to change or modify the metal surface into a thin film with desired functional properties. Conversion coatings are particularly useful for surface treatment of metals such as aluminum, zinc, and magnesium.

[0003]

[0003] When a metal surface is exposed to the elements or other operating conditions, it is susceptible to corrosion and other types of deterioration of the metal surface. For example, metal pipes in industrial facilities can be exposed to the elements or to harsh operating environments that can deteriorate or corrode the metal surface. Replacing deteriorated or corroded metal pipes is costly and often requires shutting down the industrial facility during the repair. Also, to apply a conversion coating during operation, typically a brush or sprayer must be used to manually brush the conversion coating, which can expose the operator to the chemicals within the conversion coating. Further, brushes and sprayers typically apply an excessive amount of conversion coating, which can spread to other parts of the industrial facility that were not intended to be covered, thus requiring extensive cleaning. Accordingly, there is a need for a system for applying a conversion coating to a metal surface that minimizes exposure to the chemicals within the conversion coating, minimizes cleaning after applying the conversion coating, and reduces the cost of applying the conversion coating.

Summary of the Invention

Means for Solving the Problems

[0004]

[0005] Some embodiments of a chemical applicator configured to apply a reactive chemical solution or reactive chemistry to a surface. The chemical applicator described herein typically includes a hydrogel containing a reactive chemical solution until the hydrogel and the reactive chemical solution contact the surface. The hydrogel enables the reactive chemical solution to contact the surface such that the reactive chemical solution reacts with the surface to complete desired chemical, physical, and / or mechanical changes. If the hydrogel does not react unfavorably with the reactive chemical species prior to application to the surface and enables the reactive chemical species to contact and react with the surface, the hydrogel can be configured to contain any reactive chemical species, including harmful chemical species. The chemical applicator described herein contains a reactive chemical solution in the hydrogel and, as a result of applying the reactive chemical solution to the surface, the reactive chemical solution reacts and / or the surface reacts as if it were in the reactive chemical solution and / or reduces waste, reduces mess, and reduces exposure to the reactive chemical solution. Contact between the hydrogel and the surface being coated enables the reaction to occur often without heat or other forms of energy, such as mechanical scrubbing.

[0005]

[0006] In the embodiments described herein, a reactive chemical solution is disclosed that typically can be used to form such a conversion coating, the reactive chemical solution including a conversion coating solution. The conversion coating solution generally includes trivalent chromium, hexavalent chromium, and / or non-hexavalent chromium compounds, and the conversion coating applicator also generally includes a hydrogel configured to selectively contain the conversion coating solution. In some embodiments, the conversion coating solution includes a chromium compound, a dye compound, and a zirconate compound. A method of using a conversion coating applicator to protect a metal substrate is also disclosed.

[0006]

[0007] The conversion coating solution is used to form a protective coating on the metal substrate, and the conversion coating applicator is used to apply the conversion coating solution to the metal substrate. The coating generally passivates the metal surface or, in other words, makes it less susceptible to subsequent corrosion and / or other undesirable reactions.

[0007]

[0008] The chromium compound can be any suitable chromium compound. One example of a suitable chromium compound is trivalent chromium sulfate. Of course, other chromium compounds can also be used.

[0008]

[0009] The conversion coating can be formed on the surface of the metal by use of a hydrogel filled with the conversion coating solution. The conversion coating solution is injected into the hydrogel. Then, the hydrogel is placed on the surface of the metal substrate for a period of time, and the conversion coating solution is diffused from the hydrogel onto the surface and reacted to form the conversion coating, whereby the conversion coating can be formed on the metal substrate.

[0009]

[0010] The formation coating applicator is easy to use and minimizes cleaning. The hydrogel filled with the active substance is easy to handle and use, eliminates the need for a liquid container for the formation coating, and reduces or eliminates the chemicals that flow down (drip) on the surface. The system can also be applied to preliminary chemical species - cleaning agents, activators, etc., so that the coating application and final formation do not waste chemicals and improve the safety of forming the coating. That is, because the materials are relatively contained and minimize the chance of the chemical species spilling to the user.

[0010]

[0011] There are other novel aspects and features of this disclosure, which will become apparent as this specification progresses. Accordingly, this brief summary is provided to introduce in a simplified form a selection of concepts that are further described in the detailed description below. The summary and background are not intended to identify key concepts or essential aspects of the disclosed subject matter, nor should they be used to limit or restrict the scope of the claims. For example, the scope of the claims is not limited based on whether the described subject matter includes any or all of the aspects described in the summary and / or whether it addresses any of the problems described in the background.

[0011]

[0012] Preferred and other embodiments are disclosed in connection with the accompanying drawings.

Brief Description of the Drawings

[0012]

Figure 1

[0013] A schematic side view of a formation coating applicator according to an aspect of the present disclosure is shown.

Figure 2

[0014] It is a schematic view showing a 6061 aluminum alloy with a coating applied by a Katecho (registered trademark) KM50K (registered trademark) hydrogel applicator containing a formation coating solution.

Figure 3

[0015] Another schematic view showing a 6061 aluminum alloy with a coating applied by a KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing a chemical conversion coating solution.

Figure 4

[0016] Another schematic view showing a 6061 aluminum alloy with a coating applied by a KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing a chemical conversion coating solution.

Figure 5

[0017] Another schematic view showing a 6061 aluminum alloy with a coating applied by a KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing a chemical conversion coating solution.

Figure 6

[0018] A schematic view showing the 6061 aluminum alloy of Example 4 after being subjected to a neutral salt spray test.

Figure 7

[0019] A schematic view showing the 6061 aluminum alloy after the chemical conversion coating is applied to the 6061 aluminum alloy, indicating that the 6061 aluminum alloy is water break free.

Figure 8

[0020] Another schematic view showing the 6061 aluminum alloy together with a KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing a chemical conversion coating solution for applying the coating.

Mode for Carrying Out the Invention

[0013]

[0022] Some embodiments of a reactive chemical applicator or a conversion coating applicator are disclosed, along with hydrogels, conversion coatings, and additives that can be used to form a conversion coating applicator, and a method of treating a substrate with the conversion coating applicator. Generally, a conversion coating applicator includes a hydrogel filled with a reactive chemical solution. In the illustrated embodiments, the reactive chemical solution includes a conversion coating solution. In alternative embodiments, the reactive chemical solution can be any chemical solution that enables the conversion coating applicator to operate as described herein. The hydrogel allows the conversion coating solution to be applied to limited locations on the substrate such that only limited locations on the substrate contact the conversion coating solution, minimizing contamination of other locations and minimizing contamination of the operator. The conversion coating solution can include a trivalent chromium compound, a hexavalent chromium compound, a non-hexavalent chromium compound, a zirconate compound, and / or a dye compound. The conversion coating solution can be used to improve the corrosion resistance, wear characteristics, and adhesive bonding characteristics of metals, as well as to stain metal surfaces or parts.

[0014]

[0023] The conversion coating applicator can provide one or more of the following improvements / advantages compared to conventional coating systems: 1) easier and simpler coating that reduces the amount of training required for an operator to safely apply the conversion coating to a substrate, 2) limited coating area that reduces excessive conversion coating solution application and waste of the conversion coating solution, 3) reduced cleaning, and / or 4) reduced exposure of the operator to the conversion coating solution.

[0015]

[0024] Hydrogel

[0025] Hydrogels typically contain a three-dimensional network structure of hydrophilic polymers that swell in water and contain a large amount of water compared to their volume, while maintaining their structure due to chemical or physical cross-linking of individual polymer chains. Hydrogels typically contain at least 10% water by total weight (or volume), are hydrophilic, and are flexible, such that they can conform to the shape of the surface on which they are placed. The hydrophilicity of the network structure is due to the presence of hydrophilic groups such as -NH2, -COOH, -OH, -CONH2, -CONH-, and -SO3H.

[0016]

[0026] Hydrogels can typically undergo volume phase transitions or gel-sol phase transitions in response to certain physical and chemical stimuli. Physical stimuli can include temperature, electric and magnetic fields, solvent composition, light intensity, and pressure, and chemical stimuli can include chemical reactions, pH, ions, and specific chemical compositions. Most structural transitions are reversible, and the hydrogel can return to its initial state as soon as the trigger is removed after the reaction. The response of the hydrogel to external stimuli is typically determined by the monomer type, charge density, pendant chains, and degree of cross-linking. The magnitude of the response also typically scales linearly with the applied external stimulus.

[0017]

[0027] Figure 1 shows a schematic side view of a conversion coating applicator 100 according to an aspect of the present disclosure. The conversion coating applicator 100 includes a first liner 102, a hydrogel 104, and a second liner or cover 106. Additionally, the conversion coating applicator 100 may include additional layers not shown in Figure 1. For example, the hydrogel 104 may include multiple hydrogel layers for absorbing and depositing multiple conversion coating chemicals. Additionally, the first liner 102 and the second liner 106 may also include multiple layers configured for strength, moisture retention, and adhesion, such as, but not limited to, scrim and / or non-woven scrim. The scrim and / or non-woven scrim may be part of the first liner 102, the hydrogel 104, and / or the second liner or cover 106 to provide additional support for the conversion coating applicator 100.

[0018]

[0028] The first liner 102 is configured to hold and maintain the hydrogel 104 in a predetermined position. The first liner 102 includes an inert plastic or polymer that does not absorb the hydrogel or the conversion coating chemical. The first liner 102 is flexible but holds the hydrogel and is strong enough to withstand the elements for a short period of time while the conversion coating chemical reacts with the metal substrate. Thus, the first liner 102 can include any material that is strong enough to hold the hydrogel 104, flexible enough to apply the hydrogel onto the metal substrate, resistant to absorption of the conversion chemical, and inert to the conversion coating solution. In the illustrated embodiment, the first liner 102 can include polyethylene, polyester, polypropylene, polyethylene terephthalate, medium density polyethylene, and / or polytetrafluoroethylene.

[0019]

[0029] Similarly, the second liner 106 is also configured to hold and maintain the hydrogel 104 in a predetermined position. However, the second liner 106 is configured to be removed from the hydrogel 104 prior to coating the hydrogel 104 onto the metal substrate. The second liner 106 also includes an inert plastic or polymer that does not absorb the hydrogel or the conversion coating chemical. Typically, the second liner 106 is also flexible but strong enough to hold the hydrogel for a short period of time and withstand the elements. Thus, the second liner 106 can include any material that is strong enough to hold the hydrogel 104 and resistant to absorption of the conversion chemical. In some embodiments, the second liner 106 can include the same material as the first liner 102. In the illustrated embodiment, the second liner 106 can include polyethylene, polyester, polypropylene, polyethylene terephthalate, medium density polyethylene, and / or polytetrafluoroethylene.

[0020]

[0030] The hydrogel 104 includes a polymeric hydrogel configured to (1) absorb the conversion chemical, (2) desorb the conversion chemical when the hydrogel 104 contacts the metal substrate, and (3) be inert to the conversion chemical. Thus, the hydrogel 104 can include any network structure of hydrophilic polymers that swell and hold the conversion chemical.

[0021]

[0031] For example, hydrogel 104 can include any of the following hydrogel types: homopolymeric hydrogels, cationic hydrogels, natural hydrogels, physically cross-linked hydrogels, amorphous hydrogels, copolymeric hydrogels, anionic hydrogels, synthetic hydrogels, chemically cross-linked hydrogels, semi-crystalline hydrogels, interpenetrating hydrogels, non-ionic hydrogels, hybrid hydrogels, crystalline hydrogels, hydrophilic colloid aggregation hydrogels, and / or any other type of hydrogel. If the hydrogel is a synthetic hydrogel, hydrogel 104 can include poly(vinyl alcohol), polyethylene oxide, poly(acrylic acid), poly(hydroxyethyl methacrylate), poly(glyceryl methacrylate), poly(hydroxypropyl methacrylate), polyacrylamide, poly(ethylene glycol), poly(vinyl pyrrolidone), poly(ethylene imine), polyhydric alcohols, polyacrylamide, polysaccharides, and / or any other type of polymer. If hydrogel 104 includes a natural hydrogel, hydrogel 104 can include chitosan, alginate, collagen, silk fibroin, hyaluronic acid, fibrin, gelatin, agarose, and / or any other type of natural hydrogel. Hydrogel 104 can include some commercially available hydrogels such as Actiformcool®, Aquaflo®, Clearsite®, Geliperm®, Hydrosorb®, Novogel®, Primskin®, Suprasorb G®, AquaDerm®, Tegraderm®, and / or any other commercially available hydrogel.

[0022]

[0032] As described herein, the formation coating applicator 100 is configured to hold the formation coating solution until the second liner 106 is removed and the hydrogel 104 contacts the metal substrate. The formation coating solution then reacts with the metal substrate and diffuses as the reaction consumes the formation coating solution, desorbing from the hydrogel 104 onto the metal substrate to react with the metal substrate.

[0023]

[0033] Chromium compound

[0034] In the illustrated embodiment, the reactive chemical solution includes a chromium compound for forming a formation coating on the metal substrate. The chromium compound can be any type of chromium compound including, but not limited to, trivalent chromium compounds, hexavalent chromium compounds, and non-hexavalent chromium compounds. In alternative embodiments, the reactive chemical solution can include a non-chromium compound that can form a formation coating on the metal substrate. More specifically, in the illustrated embodiment, and in the examples described herein, the reactive chemical solution includes a trivalent chromium compound.

[0024]

[0035] The trivalent chromium compound can be any suitable trivalent chromium compound capable of forming a formation coating on the metal substrate. Examples of suitable trivalent chromium compounds can be found in the patents incorporated by reference at the end of this description.

[0025]

[0036] The trivalent chromium compound can be a water-soluble trivalent chromium compound such as a trivalent chromium salt. It is generally desirable to use chromium salts that provide anions that are less corrosive than chlorides. Examples of such anions include nitrate ions, sulfate ions, phosphate ions, and acetate ions. In a preferred embodiment, the trivalent chromium compound is a sulfate of trivalent chromium. Examples of such compounds include Cr2(SO4)3, (NH4)Cr(SO4)2, or KCr(SO4)2.

[0026]

[0037] Of course, the conversion coating solution can contain one or more trivalent chromium compounds. For example, in one embodiment, the conversion coating solution contains a single trivalent chromium compound. In another embodiment, the conversion coating solution contains two, three, four, or more trivalent chromium compounds.

[0027]

[0038] The conversion coating solution can contain any suitable amount of trivalent chromium compound. Examples of suitable amounts can be found in the patents incorporated by reference at the end of this description. In some embodiments, the conversion coating solution contains approximately 0.1 g / liter (0.01 wt%) to approximately 20 g / liter (2 wt%) of trivalent chromium compound, approximately 0.2 g / liter (0.02 wt%) to approximately 10 g / liter (1 wt%) of trivalent chromium compound, or approximately 0.5 g / liter (0.05 wt%) to approximately 8 g / liter (0.8 wt%) of trivalent chromium compound.

[0028]

[0039] In other embodiments, the conversion coating solution contains at least approximately 0.1 g / liter (0.01 wt%) of trivalent chromium compound, at least approximately 0.2 g / liter (0.02 wt%) of trivalent chromium compound, or at least approximately 0.5 g / liter (0.05 wt%) of trivalent chromium compound. In still other embodiments, the conversion coating solution contains 20 g / liter (2 wt%) or less of trivalent chromium compound, 10 g / liter (1 wt%) or less of trivalent chromium compound, or 8 g / liter (0.8 wt%) or less of trivalent chromium compound.

[0029]

[0040] Dye compound

[0041] A dye compound (also referred to as a pigment compound or a colorant compound) can be any substance that is compatible with a conversion coating solution and hydrogel species and can impart color to a metal substrate. In some embodiments, the dye compound contains one or more metal atoms, and in other embodiments, it does not. In embodiments where the dye compound contains one or more metal atoms, the metal atoms can exist as part of a metal complex.

[0030]

[0042] In some embodiments, the dye compound can include azo dyes, chromium complex dyes, anthraquinoid dyes, and / or methine dyes. In preferred embodiments, the dye compound includes metal complex azo dyes, chromium complex dyes, and / or metal free azo dyes. Of course, azo dyes include monoazo dyes, disazo dyes, and / or trisazo dyes.

[0031]

[0043] Numerous other dye compounds can be used as long as they are compatible with other components in the conversion coating solution and in the hydrogel. Examples of such dyes include those used for anodizing aluminum or coloring fabrics. Other examples include acid dyes, mordant dyes, metal-complex dyes, triphenylmethane dyes, xanthene dyes, wool dyes, silk dyes, direct dyes, reactive dyes, vat dyes, and the like. It is understood that these dyes can be classified in various ways such as by structure or typical use - for example, a dye can be referred to as a chromium dye, a mordant dye, a wool dye, etc.

[0032]

[0044] Of course, the conversion coating solution can contain one or more dye compounds, including any amount and / or combination of the dyes described above. In some embodiments, the trivalent chromium conversion coating solution contains from approximately 0.1 g / liter (0.01 wt%) to approximately 20 g / liter (2 wt%) of dye compound, from approximately 0.2 g / liter (0.02 wt%) to approximately 10 g / liter (1 wt%) of dye compound, or from approximately 0.5 g / liter (0.05 wt%) to approximately 5 g / liter (0.5 wt%).

[0033]

[0045] In some other embodiments, the conversion coating solution contains at least approximately 0.1 g / liter (0.01 wt%) of dye compound, at least approximately 0.2 g / liter (0.02 wt%) of dye compound, or at least approximately 0.5 g / liter (0.05 wt%) of dye compound. In yet other embodiments, the conversion coating solution contains 20 g / liter (2 wt%) or less of dye compound, 10 g / liter (1 wt%) or less of dye compound, or 5 g / liter (0.5 wt%) or less of dye compound.

[0034]

[0046] Zirconate compound

[0047] The zirconate compound can be any suitable zirconate compound that can facilitate the formation of a protective coating on the substrate. Examples of suitable zirconate compounds include alkali metal hexafluorozirconate compounds (alkali metal hexafluorozirconate compound), such as potassium hexafluorozirconate, sodium hexafluorozirconate, and fluoro zirconic acid.

[0035]

[0048] In some embodiments, the conversion coating solution comprises from approximately 0.2 g / liter (0.02 wt%) to approximately 20 g / liter (2 wt%) of a zirconate compound, from approximately 0.5 g / liter (0.05 wt%) to approximately 18 g / liter (1.8 wt%) of a zirconate compound, or from approximately 1 g / liter (0.1 wt%) to approximately 15 g / liter (1.5 wt%) of a zirconate compound.

[0036]

[0049] In some other embodiments, the conversion coating solution comprises at least approximately 0.2 g / liter (0.02 wt%) of a zirconate compound, at least approximately 0.5 g / liter (0.05 wt%) of a zirconate compound, or at least approximately 1 g / liter (0.1 wt%) of a zirconate compound. In still other embodiments, the conversion coating solution comprises up to approximately 20 g / liter (2 wt%) of a zirconate compound, up to approximately 18.0 g / liter (1.8 wt%) of a zirconate compound, or up to approximately 15 g / liter (1.5 wt%) of a zirconate compound.

[0037]

[0050] Other compounds

[0051] The trivalent chromium conversion coating solution can include a variety of additional compounds. Examples of additional compounds can be found in patents incorporated by reference at the end of this description. The individual compounds or combinations of compounds disclosed in those patents can be included in the conversion coating solution in any of the disclosed amounts.

[0038]

[0052] In some embodiments, the trivalent chromium conversion coating solution includes a phosphorus compound that further enhances the corrosion protection of the metal substrate. The improved corrosion protection is provided by the adsorption of phosphonate groups from an organic amino-phosphonic acid compound onto the surface of the metal substrate that forms an M-O-P covalent bond and subsequently covers any active corrosion sites on the metal substrate to form a hydrophobic layer with a network structure.

[0039]

[0053] Examples of suitable phosphorus compounds include derivatives of amino - phosphonic acids, such as nitrilotris(methylene)triphosphonic acid (NTMP), hydroxy -, amino - alkylphosphonic acids, salts and esters of ethylimide(methylene)phosphonic acid, diethylaminomethylphosphonic acid, etc. Preferably, the derivative is soluble in water. A phosphorus compound particularly suitable for use as a corrosion inhibitor and a solution stabilizer is nitrilotris(methylene)triphosphonic acid (NTMP).

[0040]

[0054] The phosphorus compound can be present in the conversion coating solution in any suitable amount. In some embodiments, the conversion coating solution contains from approximately 5 ppm to approximately 100 ppm of the phosphorus compound or from approximately 10 ppm to approximately 30 ppm of the phosphorus compound. In other embodiments, the conversion coating solution contains at least approximately 5 ppm of the phosphorus compound or at least approximately 10 ppm of the phosphorus compound. In still other embodiments, the conversion coating solution contains approximately 100 ppm or less of the phosphorus compound or 30 ppm or less of the phosphorus compound.

[0041]

[0055] The trivalent chromium conversion coating solution can also contain a fluoride compound. Examples of suitable fluoride compounds include alkali metal tetrafluoroborates (e.g., potassium tetrafluoroborate), alkali metal hexafluorosilicates (e.g., potassium hexafluorosilicate), etc. The fluoride compound is preferably water - soluble.

[0042]

[0056] The fluoride compound can be present in the conversion coating solution in any suitable amount. In some embodiments, the conversion coating solution comprises from approximately 0.2 g / liter (0.02 wt%) to approximately 20 g / liter (2 wt%) of the fluoride compound or from approximately 0.5 g / liter (0.05 wt%) to approximately 18 g / liter (1.8 wt%) of the fluoride compound. In other embodiments, the trivalent chromium conversion coating solution comprises at least approximately 0.2 g / liter (0.02 wt%) of the fluoride compound or at least approximately 0.5 g / liter (0.05 wt%) of the fluoride compound. In still other embodiments, the trivalent chromium conversion coating solution comprises 20 g / liter (2 wt%) or less of the fluoride compound or 18 g / liter (1.8 wt%) or less of the fluoride compound.

[0043]

[0057] In some embodiments, the trivalent chromium conversion coating solution comprises a corrosion inhibitor additive that increases the corrosion resistance provided by the coating. Examples of suitable corrosion inhibitor compounds include any of those disclosed in CN102888138. Other examples include 2-mercaptobenzothiazole (MBT), 2-mercaptobenzimidazole (MBI), 2-mercaptobenzoxazole (MBO) and / or benzotriazole (BTA). The addition of the corrosion inhibitor compound can increase the corrosion resistance of the coating to meet the requirements of MIL-DTL-81706B Class 1A and Class 3 or the less stringent requirements of MIL-DTL-5541F Class 1A and Class 3.

[0044]

[0058] Of course, the corrosion inhibitor additive serves to substantially increase the corrosion resistance of the coating, but the coating can also meet the MIL corrosion resistance requirements in the absence of such additives.

[0045]

[0059] The trivalent chromium conversion coating solution can also contain other substances such as thickeners, surfactants, etc. Examples of these substances can be found in patents incorporated by reference at the end of this description. These substances can be included in the trivalent chromium conversion coating solution in any amount disclosed in those patents.

[0046]

[0060] Impurities

[0061] Certain impurities can reduce the corrosion resistance / color vibration of the trivalent chromium conversion coating solution. One example of such an impurity is iron (Fe). Iron impurities present in the dye can reduce the effectiveness of the coating. For example, a dye containing 0 ppm of iron can produce test plates (aluminum) that do not show corrosion for 800+ hours. However, a dye containing 10 ppm of iron can produce plates (aluminum) that do not show corrosion for 216 hours. The corrosion resistance of the latter can be increased by adjusting other parameters of the solution, such as the chromium content and / or the corrosion inhibitor content, but the result is still not as good as the situation where the dye dyes with 0 ppm of iron.

[0047]

[0062] In some embodiments, the dye and / or the trivalent chromium conversion coating solution has 100 ppm or less of iron, 50 ppm or less of iron, 25 ppm or less of iron, 10 ppm or less of iron, 5 ppm or less of iron, 2 ppm or less of iron, 1 ppm or less of iron, or preferably has no iron. The dye and / or the trivalent chromium conversion coating solution can have 0 - 100 ppm of iron.

[0048]

[0063] In some embodiments, the trivalent chromium conversion coating solution has 750 ppb or less of iron, 500 ppb or less of iron, 300 ppb or less of iron, 100 ppb or less of iron, 50 ppb or less of iron, or preferably has no iron.

[0049]

[0064] Formation of the conversion coating solution

[0065] The conversion coating solution can take various forms. In some embodiments, the conversion coating solution is the final mixed solution having various compounds at the concentrations described above. A typical example of the final mixed solution includes 1 part of trivalent chromium conversion coating solution concentrate, 1 part of dye additive, and 2 parts of water. The final mixed solution is then absorbed into the hydrogel as described herein, and the conversion coating applicator 100 can be sold as a ready-to-use product that has already been mixed.

[0050]

[0066] The trivalent chromium conversion coating solution can be used to treat any suitable metal substrate. In some embodiments, the trivalent chromium conversion coating solution can be used to treat substrates containing aluminum, magnesium, and / or zinc. The substrate can be pure or commercially pure aluminum, magnesium, or zinc. The substrate can also be an alloy of these metals or an alloy containing these metals.

[0051]

[0067] In other embodiments, the conversion coating solution can be used to treat substrates containing valve metals such as vanadium, tantalum, hafnium, niobium, and / or titanium. The substrate can be pure or commercially pure elemental valve metal. The substrate can also be an alloy of the valve metal or an alloy containing the valve metal.

[0052]

[0068] The metal substrate can be subjected to another treatment before being treated with the conversion coating solution. For example, the metal substrate can be anodized before being treated with the conversion coating solution.

[0053]

[0069] The metal substrate can take various forms. In some embodiments, the metal substrate is one or more surfaces of a larger metal member or assembly. For example, the metal substrate can be an exposed metal surface of an aircraft. In other embodiments, the metal substrate is a single member that can be made from a monolithic block of metal or created by joining a number of metal parts together.

[0054]

[0070] Preliminary chemicals in the conversion coating applicator

[0071] In some embodiments, the hydrogel 104 may contain preliminary chemicals rather than a conversion coating solution. That is, the conversion coating system can include a plurality of conversion coating applicators with different chemicals infused in the hydrogel for different stages of the conversion coating process. For example, the conversion coating process can include (a) a step of cleaning the metal substrate prior to applying the conversion coating to the metal substrate, (b) a step of activating the metal substrate prior to applying the conversion coating to the metal substrate, and (c) a step of cleaning the metal substrate after applying the conversion coating to the metal substrate. The hydrogel 104 can contain a cleaning agent, an activator, a desmutter, and / or a deoxidizer that can prepare the metal substrate prior to the conversion coating process. Specifically, the cleaning agent, the activator, the desmutter, and / or the deoxidizer can be absorbed into the hydrogel 104 prior to the conversion coating process and desorbed from the hydrogel 104 onto the metal substrate.

[0055]

[0072] Generally, to form a conversion coating on the surface of aluminum, the surface is mechanically or chemically prepared to remove soils and oxides that can inhibit coating chemistries. Mechanical preparation typically involves wiping with a solvent followed by mechanically abrading with a polishing pad. Chemical preparation typically involves cleaning and activation. Some cleaning agents can perform both cleaning and activation in a single step. The surface to be treated should / must exhibit a "water-break-free" condition prior to the conversion coating treatment. This is done by cleaning the surface and removing any loose or adherent oxides from the surface.

[0056]

[0073] Various types of cleaning agents can be used, including alkaline or acidic cleaning agents. Cleaning agents are generally non-etching in aluminum applications, although in some cases an etching cleaning agent is desired. In the manufacturing process, these cleaning agents are generally heated to be effective. Cold cleaning agents do not function well in the dipping, spraying, or brushing processes. Various types of activators can be used, including acidic activators containing nitric acid. Additionally, the cleaning agent and / or activator can include a smut remover or deoxidizer. The term "deoxidizer" refers to the solution ability to remove oxides from the surface. Deoxidizers contain strong oxidizing compounds such as persulfates or peroxides and are usually acidic. The acidic components can include acids such as sulfuric acid, nitric acid, chromic acid, and hydrofluoric acid. These acids can be used individually or in combination. Fluorides are often added to enhance the removal of silicon and magnesium compounds. Ferric iron in the ferric form is used as an oxidizing agent. Other chemical pretreatments include alkaline etching.

[0057]

[0074] Method for forming a conversion coating applicator

[0075] A variety of methods can be used to form a formation coating applicator. Generally, the method can include one or more of the steps of: (a) forming a first liner; (b) forming a formation coating solution; (c) forming a hydrogel on the first liner; (d) injecting the formation coating solution into the hydrogel; (e) attaching a second liner to the hydrogel; and / or (f) hermetically packaging the formation coating applicator for storage. In some embodiments, step (d) of injecting the formation coating solution into the hydrogel can include immersing the hydrogel and the first liner in the formation coating solution and diffusing the formation coating solution into the hydrogel. In another embodiment, step (d) of injecting the formation coating solution into the hydrogel can include spraying the formation coating solution onto the hydrogel and the first liner and diffusing the formation coating solution into the hydrogel. In yet another embodiment, step (d) of injecting the formation coating solution into the hydrogel can include mixing the formation coating solution into a polymer prior to (c) forming the hydrogel on the first liner and simultaneously forming the hydrogel on the first liner with (c) the formation coating solution.

[0058]

[0076] In addition, in some embodiments, the hydrogel can be formed on the first liner in a particular predetermined arrangement. For example, in some embodiments, the metal substrate on which the formation coating applicator is used can have a particular shape. To reduce waste, the hydrogel can be formed on the first liner such that the hydrogel has a shape corresponding to the particular shape of the metal substrate (substate). The formation coating applicator is applied on the metal substrate as described herein, and the corresponding shapes of the metal substrate and the hydrogel allow the formation coating applicator to target a particular area of the metal substrate (substate), reducing waste. More specifically, as shown in FIGS. 2-8, the hydrogel can form a sharp-edged rim or line on the metal substrate. That is, the formation coating solution does not flow out beyond the hydrogel on the metal substrate, and by shaping the hydrogel to correspond to the shape of a particular area of the metal substrate, it is possible to reduce the amount of the formation coating solution used for the formation coating applicator to form the coating described herein. Further, the hydrogel can be shaped after being formed on the first liner. For example, the hydrogel can be cut using a cutting device or method (e.g., laser trimming, X-Y moving blade cutter, die cut, etc.) after formation to form the hydrogel into a shape corresponding to the particular shape of a portion of the metal substrate (substate).

[0059]

[0077] Method for forming a preliminary formation coating applicator

[0078] A variety of methods can be used to form a preliminary formation coating applicator. Generally, the method can include one or more of the steps of: (a) forming a first liner; (b) forming a formation coating solution; (c) forming a hydrogel on the first liner; (d) injecting a preliminary solution into the hydrogel; (e) attaching a second liner to the hydrogel; and / or (f) hermetically packaging the preliminary formation coating applicator for storage. In some embodiments, step (d) of injecting a preliminary solution into the hydrogel can include immersing the hydrogel and the first liner in the preliminary solution and diffusing the preliminary solution into the hydrogel. In another embodiment, step (d) of injecting a preliminary solution into the hydrogel can include spraying the preliminary solution onto the hydrogel and the first liner and diffusing the preliminary solution into the hydrogel. In yet another embodiment, step (d) of injecting a preliminary solution into the hydrogel can include mixing the preliminary solution into a polymer prior to step (c) of forming a hydrogel on the first liner and simultaneously forming a hydrogel on the first liner with the preliminary solution.

[0060]

[0079] Method for treating a metal substrate with a formation coating application system or applicator

[0080] A variety of methods can be used to process a metal substrate with a conversion coating application system or applicator. Generally, the method can include one or more of the steps of: (a) cleaning the metal substrate; (b) activating the metal substrate; (c) applying a trivalent chromium conversion coating solution to the metal substrate (e.g., applying a conversion coating applicator to the metal substrate); (d) rinsing the conversion coating solution from the metal substrate; and (e) drying the metal substrate (either actively or passively). In some embodiments, the step of (a) cleaning the metal substrate can include applying a cleaning applicator having a cleaning solution in a hydrogel to the metal substrate. In some embodiments, the step of (b) activating the metal substrate can include applying an activator applicator having an activation solution in a hydrogel to the metal substrate. In some embodiments, the step of (d) rinsing the conversion coating solution from the metal substrate can include applying a cleaning applicator having a cleaning solution in a hydrogel to the metal substrate.

[0061]

[0081] Note that since the dye is an integral part of the trivalent chromium conversion coating solution, the process of coating and staining the substrate can be done in a single step. Many conventional methods for staining metal substrates are two-step processes. The first step of such a process is typically to apply a conversion coating, typically by dipping the substrate into a bath. The second step of such a process is to apply the dye, which is also typically done by dipping. This process can apply the conversion coating and color the substrate simultaneously.

Example

[0062]

[0082] Example

[0083] The following examples are provided to further illustrate the disclosed subject matter and should not be used to limit or restrict the scope of the claims in any way.

[0063]

[0084] Example 1

[0085] A first sample of a metal substrate (aluminum) was coated with a conversion coating solution (CHEMEON eTCP) using the conversion coating applicator described herein. No preparation of the metal surface (solvent, water, or abrasive cleaning) was used - the surface of the aluminum was left as received from the supplier. The conversion coating applicator was formed by immersing a Katecho® KM50K® hydrogel applicator in a conversion coating solution containing a trivalent chromium compound for 2 minutes. The Katecho® KM50K® hydrogel applicator acquires a purple color from the conversion coating solution after 8 minutes of contact with the surface. The Katecho® KM50K® hydrogel applicator containing the conversion coating solution is placed on a 6061 aluminum alloy.

[0064]

[0086] Figure 2 is a schematic view showing a 6061 aluminum alloy having a coating applied by a Katecho® KM50K® hydrogel applicator containing a conversion coating solution. As shown in Figure 2, a conversion coating, shown as a shaded area on the substrate, is visibly formed on the 6061 aluminum alloy. Thus, the conversion coating applicator described herein can form a conversion coating that can protect the 6061 aluminum alloy from degradation.

[0065]

[0087] Example 2

[0088] A second sample (aluminum) of the metal substrate was coated with a conversion coating solution (CHEMEON eTCP) using the conversion coating applicator described herein. The conversion coating applicator was formed by immersing a Katecho® KM50K® hydrogel applicator in a conversion coating solution containing 8 g / L of a trivalent chromium compound for 5 minutes. The aluminum substrate was prepared by wiping with isopropanol to remove organic residues on the surface. The Katecho® KM50K® hydrogel applicator acquires a purple color from the conversion coating solution. The Katecho® KM50K® hydrogel applicator containing the conversion coating solution was placed on the 6061 aluminum alloy for 8 minutes.

[0066]

[0089] Figure 3 is a schematic view showing a 6061 aluminum alloy having a coating applied by a Katecho® KM50K® hydrogel applicator containing a conversion coating solution. As shown in Figure 3, a conversion coating is formed on the 6061 aluminum alloy such that it is clearly visible on the substrate as a shaded area darker than the shaded area shown in Figure 2. Thus, the conversion coating applicator described herein can form a conversion coating that can protect the 6061 aluminum alloy from degradation.

[0067]

[0090] Example 3

[0091] A third sample (aluminum) of the metal substrate was coated with a conversion coating solution (CHEMEON eTCP) using the conversion coating applicator described in this specification. The conversion coating applicator was formed by immersing the KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) in a conversion coating solution containing 12 g / L of a trivalent chromium compound for 10 minutes. The KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) acquires a dark purple color from the conversion coating solution. The KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing the conversion coating solution was placed on the 6061 aluminum alloy for 8 minutes. The 6061 alloy aluminum substrate was first wiped with isopropanol to remove fingerprints and other handling residues, then roughly abraded with a Scotch Brite 07447 pad for 30 seconds, and finally wiped with isopropanol to remove the polishing finish fine particles.

[0068]

[0092] Figure 4 is a schematic view of a 6061 aluminum alloy with a coating applied by the KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing a conversion coating solution. As shown in Figure 4, a conversion coating is formed on the 6061 aluminum alloy such that the conversion coating shown on the substrate as a shaded area darker than the shaded areas shown in Figures 2 and 3 is clearly visible to the naked eye. Specifically, the conversion coating has a bluish-purple hue on the 6061 aluminum alloy. The edge of the contact area is sharp and prominent. Therefore, the conversion coating applicator described in this specification can form a conversion coating that can protect the 6061 aluminum alloy from degradation.

[0069]

[0093] Example 4

[0094] A fourth sample (aluminum) of a metal substrate was coated with a conversion coating solution (CHEMEON eTCP) using the conversion coating applicator described herein. The conversion coating applicator was formed by immersing a Katecho® KM50K® hydrogel applicator containing 12 g / L of a trivalent chromium compound in the conversion coating solution for 10 minutes. The Katecho® KM50K® hydrogel applicator acquires a dark purple color from the conversion coating solution. The Katecho® KM50K® hydrogel applicator containing the conversion coating solution was placed on a 6061 aluminum alloy for 8 minutes. In Example 4, the Katecho® KM50K® hydrogel applicator containing the conversion coating solution had an area of approximately 7.62 cm (3 inches) × 12.7 cm (5 inches) to test the ability of the Katecho® KM50K® hydrogel applicator to form a conversion coating over a larger area.

[0070]

[0095] Figure 5 is a schematic view showing a 6061 aluminum alloy having a coating applied by a KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing a conversion coating solution. The hydrogel applicator was prepared by immersing KM50K in a solution of trivalent chromium conversion coating at 12 g / L for 10 minutes at room temperature. The 6061 aluminum substrate was prepared by wiping the surface with acetone followed by isopropanol, mechanically abrading with a Scotch Brite 07447 pad, and wiping again with acetone followed by isopropanol. The hydrogel applicator was applied to the prepared aluminum at room temperature for 8 minutes. At the end of the application time, the aluminum panel was rinsed and dried, except for the hydrogel. As shown in Figure 5, a conversion coating, shown as the shaded portion on the substrate, is clearly visible on the 6061 aluminum alloy. In particular, the conversion coating has a prominent blue color on the 6061 aluminum alloy. The bright portions of the coated substrate are also coated, but the coating in those portions is less. The portions with less coating are due to the wrinkles of the hydrogel applicator. Thus, the conversion coating applicator described herein can form a conversion coating that can protect the 6061 aluminum alloy from degradation.

[0071]

[0096] Example 5

[0097] The 6061 aluminum alloy coated in Example 4 was subjected to a neutral salt spray test for 528 hours. The test protocol follows ASTM B117 IAW MIL-DTL-5541 and MIL-DTL-81706. Figure 6 is a schematic view showing the 6061 aluminum alloy of Example 4 after being subjected to the neutral salt spray test. As shown in Figure 6, the 6061 aluminum alloy of Example 4 does not undergo significant corrosion. Thus, the coating formed by the KM50K (registered trademark) hydrogel applicator of Katecho (registered trademark) containing a conversion coating solution protects the aluminum alloy from corrosion.

[0072]

[0098] Example 6

[0099] The fifth sample (6061 aluminum alloy) of the metal substrate was coated with a cleaning solution using the cleaning applicator described in this specification. The cleaning applicator was formed by immersing a Katecho® KM50K® hydrogel applicator in a cleaning solution of 45 g / L of Chemeon® Cleaner 1000®, which is an alkaline borax-based cleaner. The Katecho® KM50K® hydrogel applicator was immersed in the cleaning solution for 20 minutes. The Katecho® KM50K® hydrogel applicator containing the cleaning solution was placed on the upper region of the 6061 aluminum alloy at room temperature for 25 minutes. As shown in FIG. 7, the Katecho® KM50K® hydrogel applicator containing the cleaning solution produced a water-break-free surface. The water-break-free state indicates that the hydrogel-filled cleaning applicator effectively cleaned the surface.

[0073]

[0100] Example 7

[0101] An applicator example showing the Katecho KM50K applicator in use, FIG. 8. The applicator was immersed in a solution of trivalent chromium conversion coating, 12 g / L of CHEMEON eTCP conversion coating. The immersion time was 5 minutes. The applicator maintained its shape and adhered well to the surface. The absorbed chemicals did not drip or flow. That is, it shows that the applicator can target selective areas and minimize the exposure of chemicals to the workers applying the coating.

[0074]

[0102] Terms and Interpretation Conventions

[0103] Any method described in the claims or the specification should not be construed as requiring steps to be performed in a particular order unless otherwise specified. Also, unless otherwise specified, these methods should be construed as providing support for performing the stated steps in any order.

[0075]

[0104] Spatial or directional terms, such as "left", "right", "front", "rear", etc., relate to the subject shown in the drawings. However, it should be understood that the described subject may assume various alternative orientations, and thus such terms should not be considered limiting.

[0076]

[0105] Articles such as "the", "a", and "an" can indicate singular or plural. Also, the word "or" is to be interpreted inclusively when used without an accompanying "either" (or other similar words that clearly mean "or" is exclusive - e.g., only one of x or y, etc.) (e.g., "x or y" means one or both of x or y).

[0077]

[0106] The term "and / or" is also to be interpreted inclusively (e.g., "x and / or y" means one or both of x or y). In situations where "and / or" or "or" is used as a conjunction for a group of three or more items, the group should be interpreted to include any one item alone, all items, or any combination or several of the items.

[0078]

[0107] The terms "have", "having", "include", and "including" should be interpreted as synonymous with the terms "comprise" and "comprising". The use of these terms should also be understood to disclose and provide support for narrower alternative embodiments in which these terms are replaced by "consisting of" or "consisting essentially of".

[0079]

[0108] Unless otherwise indicated, all numbers or expressions representing dimensions, physical characteristics, etc. used in this specification (other than the claims) are to be understood as being modified in all instances by the term "about". At a minimum, and without limiting the application of the doctrine of equivalents to the claims, each numerical parameter modified by the term "about" recited in this specification or in the claims is to be construed in light of the recited number of significant digits and by applying ordinary rounding techniques.

[0080]

[0109] All disclosed ranges are to be understood to provide support for claims that recite any and all sub-ranges or any and all individual values subsumed within each range. For example, the recited range of 1 to 10 is to be considered to provide support for claims that recite any and all sub-ranges or individual values therebetween, including the endpoints of the minimum value of 1 and the maximum value of 10; that is, all sub-ranges that begin with a minimum value of 1 or more and end with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, etc.) or any value from 1 to 10 (e.g., 3, 5.8, 9.9994, etc.).

[0081]

[0110] All disclosed numerical values are to be understood as being able to vary by 0 - 100% in either direction, and thus provide support for claims that recite any and all ranges or sub-ranges that can be formed by such values or such values. For example, the recited numerical value of 8 is to be understood as varying from 0 to 16 (100% in either direction), and provides support for claims that recite the range itself (e.g., 0 to 16), any sub-range within that range (e.g., 2 to 12.5) or any individual value within that range (e.g., 15.2).

[0082]

[0111] The terms recited in the claims are given their ordinary and customary meaning as determined with reference to widely used general dictionaries and / or relevant entries in related technical dictionaries, the meaning generally understood by one of ordinary skill in the art, etc., but only the following exceptions apply under the understanding that the broadest meaning imparted by any one or combination of these information sources should be given to the terms of the claims (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of a combination of terms, etc.): (a) If a term is used in a broader scope than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus an additional broadened meaning, or (b) If a term is clearly defined to have a different meaning by virtue of being accompanied by a phrase such as "when used in this document means ~" or similar words (e.g., "this term means ~", "this term is defined as ~", "for the purposes of this disclosure this term means ~", etc.). References to specific examples, use of "i.e.", use of the word "invention", etc. do not cause exception (b) to apply or otherwise limit the scope of the terms of the claims as stated elsewhere. Except in situations where exception (b) applies, this document does not contain any statement that could be considered a disclaimer or denial of the claims.

[0083]

[0112] The subject matter recited in the claims does not have the same scope as, and should not be construed to have the same scope as, any embodiment, feature, or combination of features described or shown in this document. This is true even if only a single embodiment of a feature or combination of features is shown and described in this document.

[0084]

[0113] Incorporation by reference

[0114] The entire contents of each of the documents listed below are hereby incorporated by reference into this document. If the same term is used in both this document and one or more of the incorporated documents, and the term is not explicitly defined to have a different meaning in this document, then it should be interpreted to have the broadest meaning given by any one of these sources or the combination. If there is any conflict between any of the following documents and this document, this document shall apply. The incorporated subject matter shall not be used to limit or narrow the scope of the explicitly stated or depicted subject matter. -U.S. Provisional Application No. 62 / 453,495, filed on February 1, 2017, entitled "Dyed Non-Hexavalent Chromium Conversion Coating" (attached hereto). -U.S. Provisional Application No. 62 / 588,129, filed on November 17, 2017, entitled "Dyed Trivalent Chromium Conversion Coatings" (attached hereto). -U.S. Patent Application No. 62 / 732,101, filed on December 31, 2019, and published on May 7, 2020, entitled "Dyed Trivalent Chromium Conversion Coatings and Methods of Using Same". -U.S. Patent No. 10,533,254, issued on January 14, 2020, entitled "Dyed Trivalent Chromium Conversion Coatings and Methods of Using Same". -U.S. Patent Application No. 16 / 552,996, filed on August 27, 2019, and published on December 19, 2019, entitled "pH Stable Trivalent Chromium Coating Solutions". - U.S. Patent No. 10,400,338, titled "pH Stable Trivalent Chromium Coating Solutions", issued on September 3, 2019. - U.S. Patent No. 8,486,203 (Application No. 12 / 706,360), titled "Conversion Coating and Anodizing Sealer with No Chromium", filed on February 16, 2010 and issued on June 26, 2013. - U.S. Patent No. 6,375,726 (Application No. 09 / 702,225), titled "Corrosion Resistant Coatings for Aluminum and Aluminum Alloys", filed on October 31, 2000 and issued on April 23, 2002. - U.S. Patent No. 6,511,532 (Application No. 10 / 012,982), titled "Post-Treatment for Anodized Aluminum", filed on November 6, 2001 and issued on January 28, 2003. - U.S. Patent No. 6,521,029 (Application No. 10 / 116,844), titled "Pretreatment for Aluminum and Aluminum Alloys", filed on April 5, 2002 and issued on February 18, 2003. - U.S. Patent No. 6,527,841 (Application No. 10 / 012,981), titled "Post-Treatment for Metal Coated Substrates", filed on November 6, 2001 and issued on March 4, 2003. U.S. Patent No. 6,669,764 (Application No. 10 / 351,752), entitled "Pretreatment for Aluminum and Aluminum Alloys", filed on January 23, 2003 and issued on December 30, 2003. U.S. Patent No. 7,018,486 (Application No. 10 / 187,179), entitled "Corrosion Resistant Trivalent Chromium Sulfated Chemical Conversion Coatings", filed on June 27, 2002 and issued on March 28, 2006. The part (attached to this application) that discloses and describes the corrosion inhibitor compound of Chinese Patent Application Publication No. 102888138, entitled "Low-temperature anti-corrosion protective agent for surfaces of automobile parts", published on January 23, 2013.

Claims

1. A conversion coating applicator, comprising: a first liner, a hydrogel attached to the first liner, and a second liner removably attached to the hydrogel , wherein the hydrogel contains a trivalent chromium compound, a zirconate compound, and a dye compound and contains a trivalent chromium conversion coating solution, wherein the conversion coating solution is an aqueous solution, the conversion coating applicator.

2. The conversion coating applicator according to claim 1, wherein the trivalent chromium compound contains a sulfate of trivalent chromium.

3. The conversion coating applicator according to claim 1, wherein the hydrogel contains an alginate hydrogel.

4. The conversion coating applicator according to claim 1, wherein the hydrogel contains sodium alginate hydrogel.

5. The conversion coating applicator according to claim 1, wherein the zirconate compound contains an alkali metal hexafluorozirconate compound.

6. The conversion coating applicator according to claim 1, containing approximately 0.2 g / l to approximately 20 g / l of the zirconate compound.

7. The conversion coating applicator according to claim 1, wherein the dye compound contains a metal complex azo dye.

8. The conversion coating applicator according to claim 1, wherein the dye compound contains a chromium complex azo dye.

9. The conversion coating applicator according to claim 1, wherein the dye compound contains a metal-free azo dye.

10. The conversion coating applicator according to claim 1, containing approximately 0.01 wt% to approximately 2.0 wt% of the dye compound.

11. The conversion coating applicator according to claim 1, containing a phosphorus compound.

12. The conversion coating applicator according to claim 1, wherein the trivalent chromium conversion coating meets the requirements of MIL-DTL-81706B Class 1A and Class 3 and / or MIL-DTL-5541F Class 1A and Class 3.

13. The conversion coating applicator according to claim 1, containing 2-mercaptobenzothiazole, 2-mercaptobenzimidazole, 2-mercaptobenzoxazole, and / or benzotriazole.

14. The conversion coating applicator according to claim 1, wherein the trivalent chromium conversion coating solution has a pH of approximately 2.5 to approximately 4.

5.

15. A method comprising the step of treating a metal substrate with the conversion coating applicator according to claim 1, shaping the conversion coating applicator into a shape corresponding to a specific shape of the metal substrate, and placing the conversion coating applicator on the metal substrate such that the hydrogel contacts the metal substrate The method comprising the above steps.

16. The method according to claim 15, wherein the metal substrate contains aluminum, magnesium, and / or zinc.

17. A conversion coating application system, a conversion coating applicator, a first liner, a first hydrogel attached to the first liner, and a first cover removably attached to the first hydrogel The conversion coating applicator comprising the above components, wherein the first hydrogel contains a trivalent chromium compound, a zirconate compound, and a dye compound and contains a trivalent chromium conversion coating solution, wherein the conversion coating solution is an aqueous solution, and the conversion coating applicator, an activation applicator, a second liner, a second hydrogel attached to the second liner, and a second cover removably attached to the second hydrogel The activation applicator comprising the above components, wherein the second hydrogel contains an activation solution, and the activation applicator The conversion coating application system comprising the above components.

18. A cleaning applicator, a third liner, a third hydrogel attached to the third liner, and a third cover removably attached to the third hydrogel The cleaning applicator comprising the above components, wherein the third hydrogel contains a cleaning solution, and the cleaning applicator The conversion coating application system according to claim 17, further comprising the above cleaning applicator.

19. A method comprising the step of treating a metal substrate with the conversion coating application system according to claim 18, the method comprising placing the conversion coating applicator on the metal substrate such that the first hydrogel contacts the metal substrate.

20. Placing the cleaning applicator on the metal substrate such that the third hydrogel contacts the metal substrate; Placing the activation applicator on the metal substrate such that the second hydrogel contacts the metal substrate; The method according to claim 19, further comprising.

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