Metal gasket material plate and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-10151393-B2
Application number	US-201615067416-A
Country	US
Kind code	B2
Filing date	Mar 11, 2016
Priority date	Mar 12, 2015
Publication date	Dec 11, 2018
Grant date	Dec 11, 2018

Abstract

A metal gasket material plate includes a sealing layer formed by layering a chemical coating layer, an adhesive layer, and a rubber coating layer in this order on at least one side of a metal plate. The chemical coating layer is formed by a thermosetting surface preparation agent including inorganic compound particles and a metal alkoxide compound. The adhesive layer is formed by an adhesive including an epoxy compound and an anti-corrosive pigment. The rubber coating layer is formed by a rubber agent including rubber.

First claim

The invention claimed is:

1. A metal gasket material plate comprising:
a sealing layer formed by layering a chemical coating layer, an adhesive layer, and a rubber coating layer in order on at least one side of a metal plate, wherein
the chemical coating layer is formed by a thermosetting surface preparation agent including inorganic compound particles and a metal alkoxide compound,
the adhesive layer is a layer with a thickness of 2 μm to 5 μm formed by an adhesive that includes at least one epoxy compound selected from the group consisting of a novolac epoxy compound, a bisphenol A epoxy compound, a bisphenol F epoxy compound, a cresol novolac epoxy compound, a naphthalene epoxy compound, a glycidyl ester epoxy compound, a glycidylamine epoxy compound, a heterocyclic epoxy compound, and a rubber-modified epoxy compound, and at least one anti-corrosive pigment selected from the group consisting of a phosphoric acid anti-corrosive pigment, a molybdic acid anti-corrosive pigment, and a phosphomolybdic acid anti-corrosive pigment,
the rubber coating layer is formed by a rubber agent including rubber, and
an average length of the anti-corrosive pigment is 0.5 μm to 4 μm, and a proportion of the anti-corrosive pigment is 10% to 30% by weight with respect to 100% by weight of the epoxy compound.

2. The metal gasket material plate of claim 1 , wherein anti-corrosive pigment is substantially not included in the rubber coating layer.

3. The metal gasket material plate of claim 1 , wherein
a thickness of the chemical coating layer is 1 μm to 2 μm,
the inorganic compound particles comprise at least one type of particle selected from the group consisting of silica, alumina, and titanium, and
the metal alkoxide compound comprises at least one compound selected from the group consisting of titanate, a silane coupling agent, and aluminate.

4. The metal gasket material plate of claim 3 , wherein
the rubber is acrylonitrile butadiene rubber,
a thickness of the rubber coating layer is 15 μm to 35 μm, and
a universal hardness of the rubber coating layer in an ultra-microhardness tester is 20 N/mm 2 to 120 N/mm 2 .

5. The metal gasket material plate of claim 4 , wherein anti-corrosive pigment is substantially not included in the rubber coating layer.

6. The metal gasket material plate of claim 3 , wherein anti-corrosive pigment is substantially not included in the rubber coating layer.

7. The metal gasket material plate of claim 1 , wherein
the rubber is acrylonitrile butadiene rubber,
a thickness of the rubber coating layer is 15 μm to 35 μm, and
a universal hardness of the rubber coating layer in an ultra-microhardness tester is 20 N/mm 2 to 120 N/mm 2 .

8. The metal gasket material plate of claim 7 , wherein anti-corrosive pigment is substantially not included in the rubber coating layer.

9. A method for manufacturing a metal gasket material plate, the method comprising:
forming a chemical coating layer by applying a thermosetting surface preparation agent including inorganic compound particles and a metal alkoxide compound onto at least one side of a metal plate and then drying and heating the thermosetting surface preparation agent;
forming an adhesive layer with a thickness of 2 μm to 5 μm by applying, onto the chemical coating layer, an adhesive that includes at least one epoxy compound selected from the group consisting of a novolac epoxy compound, a bisphenol A epoxy compound, a bisphenol F epoxy compound, a cresol novolac epoxy compound, a naphthalene epoxy compound, a glycidyl ester epoxy compound, a glycidylamine epoxy compound, a heterocyclic epoxy compound, and a rubber-modified epoxy compound, and at least one anti-corrosive pigment selected from the group consisting of a phosphoric acid anti-corrosive pigment, a molybdic acid anti-corrosive pigment, and a phosphomolybdic acid anti-corrosive pigment and then drying and heating the adhesive; and
forming a rubber coating layer by applying a rubber agent including rubber onto the adhesive layer and then drying and heating the rubber agent, wherein
an average length of the anti-corrosive pigment is 0.5 μm to 4 μm, and a proportion of the anti-corrosive pigment is 10% to 30% by weight with respect to 100% by weight of the epoxy compound.

Assignees

• Nippon Leakless Ind Co Ltd
• Honda Motor Co Ltd

Inventors

• Ota Satoshi
• Mitsuyama Naomichi
• Yoshizawa Yosuke
• Mitsumori Yuji
• Sasaki Kenji
• Nakamura Masayuki
• Okubo Akihiro
• Masukura Akira
• Kitagawa Noriyuki

Classifications

• F16J15/0818 Primary

  Flat gaskets · CPC title

• F02F11/002

  involving cylinder heads · CPC title

• B05D2202/00

  Metallic substrate · CPC title

• F16J15/0806 Primary

  characterised by material or surface treatment · CPC title

• F16J15/122

  generally parallel to the surfaces · CPC title