Surface-Treated Metal Material with Composite Coating
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Solution Overview
Problem
Conventional surface treatments on metal materials with multiple phases can lead to uneven corrosion resistance, requiring increased inhibitor content which compromises coating adhesion and other performance metrics.
Innovation Solution
A surface-treated metal material with a composite coating containing organic silicon, zirconium, titanium, phosphoric acid, and vanadium compounds, where the vanadium compound is unevenly distributed to concentrate in regions of low corrosion resistance without increasing overall inhibitor content, enhancing corrosion resistance while maintaining adhesion and other properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the content of inhibitor is increased to ensure sufficient corrosion resistance, then corrosion resistance is improved, but coating adhesion and other performance deteriorate
Solution Approach 1:
The patent applies local quality by creating regions with different vanadium compound concentrations within the composite coating. Specifically, it forms a first region with a first vanadium compound concentration and a second region with a second vanadium compound concentration that is higher than the first. This non-uniform distribution allows localized enhancement of corrosion resistance in the second region without requiring a uniform increase in inhibitor content across the entire coating, thereby maintaining coating adhesion and other performance characteristics.
2Ease of manufacture
If a conventional surface treatment is applied to metal material with multiple phases, then the treatment process is simple, but uneven corrosion resistance occurs on the surface
Solution Approach 1:
The patent addresses corrosion resistance uniformity by implementing local quality through a composite coating with spatially varying vanadium compound concentrations. The coating contains a first region and a second region with different vanadium concentrations, where the second region has higher concentration to compensate for locally weaker corrosion resistance. This approach maintains relatively simple treatment processes while achieving uniform overall corrosion resistance through strategic local enhancement.
Solution Approach 2:
The patent employs composite materials by creating a composite coating that incorporates multiple compounds including vanadium compound, zinc compound, and aluminum compound in specific combinations. This composite structure allows the coating to achieve enhanced and uniform corrosion resistance across multi-phase metal surfaces by leveraging the synergistic effects of different compounds distributed in specific concentration patterns.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures consistent corrosion resistance across the metal surface, improving heat resistance, fingerprint resistance, conductivity, and coatability without deteriorating coating adhesion or increasing inhibitor levels.
Implementation Method 1
when a surface of the composite coating is analyzed at a spot size of φ30 μm using micro-fluorescent X-rays, a maximum value of V/Zn, which is a mass ratio of a V content to a Zn content, is 0.010 to 0.100
Implementation Method 2
a method of forming a dense siloxane film by crosslinking the organic functional silane with the crosslinking agent
Implementation Method 3
a method of forming a dense siloxane film by crosslinking the organic functional silane with the crosslinking agent
Implementation Method 4
the treatment solution is applied to the surface of a metal material, and the treatment solution is heated and dried to form a coating containing a reaction product of the silane coupling agent I and the silane coupling agent II
Data Source
AI summary
A surface-treated metal material includes a metal sheet, a plating layer formed on the metal sheet and containing aluminum, magnesium, and zinc, and a composite coating formed on a surface of the plating layer, the composite coating including an organic silicon compound, one or two of a zirconium compound and a titanium compound, a phosphoric acid compound, a fluorine compound, and a vanadium compound, wherein, when a surface of the composite coating is analyzed at a spot size of φ30 μm using micro-fluorescent X-rays, a maximum value of V/Zn, which is a mass ratio of a V content to a Zn content, is 0.010 to 0.100.