Surface Treatment Agent for Metal Materials
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Solution Overview
Problem
Current techniques for metallic materials lack a method to achieve excellent initial rust resistance, lubrication, and corrosion resistance of paint films without the need for rust preventive oil or surface preparation treatments like phosphate-based or zirconium-based chemical conversion processes.
Innovation Solution
A surface-treating agent comprising a zirconium compound, an aqueous epoxy resin with a carboxyl group-containing polymer, and a hydroxycarboxylic acid, applied in specific ratios, along with optional silane and lubricant components, to form a coating that enhances rust resistance and paint adhesion without requiring degreasing or chemical conversion treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rust preventive oil is applied to metallic materials, then initial rust resistance is improved, but the process complexity increases and environmental waste increases due to required degreasing treatment
Solution Approach 1:
The invention extracts and eliminates the rust preventive oil application step and subsequent degreasing treatment from the processing sequence. By directly applying the epoxy resin-containing surface treatment agent to the metal surface, the patent removes the intermediate rust preventive oil layer and the necessary removal process, achieving both initial rust resistance and process simplification
Solution Approach 2:
The surface treatment agent serves multiple functions simultaneously: it provides initial rust resistance, ensures adequate lubrication for subsequent processing, and creates a surface suitable for painting without requiring separate degreasing or surface preparation steps. This multi-functionality resolves the contradiction by consolidating multiple required properties into a single treatment
2Reliability
If phosphate-based or zirconium-based chemical conversion treatment is applied before painting, then corrosion resistance and paint adhesion are improved, but the process complexity and production time increase
Solution Approach 1:
The invention merges the functions of chemical conversion treatment (for corrosion resistance and paint adhesion) with the surface treatment agent application step. The epoxy resin-containing agent performs both the surface preparation function and the adhesion promotion function that would otherwise require separate phosphate or zirconium-based chemical conversion treatment, thereby eliminating process steps and improving productivity
Solution Approach 2:
The surface treatment agent is applied in advance to create a surface layer that inherently provides both corrosion resistance and paint adhesion properties. This preliminary action eliminates the need for subsequent chemical conversion treatment before painting, as the required surface properties are already established by the initial application of the epoxy resin-containing agent
3Productivity
If organic coating is applied without rust preventive oil, then initial rust resistance and lubrication are improved, but corrosion resistance under severe conditions deteriorates
Solution Approach 1:
The invention changes the chemical composition parameters of the surface treatment agent by incorporating epoxy resin with specific acid value ranges (5-50 mg KOH/g) and controlling the ratio of epoxy resin to other components. These parameter changes enable the coating to achieve both good initial rust resistance and adequate corrosion resistance under severe conditions, while maintaining production efficiency
4Object-generated harmful factors
If degreasing treatment is omitted to improve environmental sustainability, then initial rust resistance deteriorates
Solution Approach 1:
The surface treatment agent is applied as a preliminary treatment that inherently provides initial rust resistance without requiring prior degreasing. The epoxy resin-containing agent creates a protective surface layer that prevents rust formation directly on the metal surface, eliminating the need for degreasing treatment while maintaining adequate initial rust resistance
Solution Approach 2:
The epoxy resin-containing surface treatment agent acts as an intermediary substance that bonds to the metal surface and provides rust protection without requiring the removal of organic contaminants. This intermediary layer creates a barrier between the metal and the environment, allowing the system to function without degreasing treatment
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 provides metallic materials with superior initial rust resistance, lubrication, and corrosion-resistant paint films, while eliminating the need for surface preparation treatments, thereby improving production efficiency and environmental sustainability.
Implementation Method 1
a surface-treating agent for metallic materials that contains a zirconium compound, an aqueous epoxy resin and a hydroxycarboxylic acid
Implementation Method 2
an aqueous epoxy resin having, in its skeleton, a carboxyl group-containing polymer containing a repeating unit derived from a carboxyl group-containing vinyl monomer
Data Source
AI summary
Provided is a surface treatment agent for a metal material with which it is possible to produce a surface-treated metal material that has excellent initial anti-rust properties without being coated with an anti-rust oil, excellent lubrication properties, and excellent anti-corrosion and adhesion properties in a coating film for which phosphate-based chemical conversion treatment, zirconium-based chemical conversion treatment, or other coating underlay processing is omitted. This surface treatment agent for a metal material contains: a zirconium compound; an aqueous epoxy resin having in the skeleton thereof a carboxyl-group-containing polymer that includes a repeated unit derived from a carboxyl-group-containing vinyl monomer, said aqueous epoxy resin also having an acid value of 5-50 mg KOH/g; and a hydroxycarboxylic acid.