Corrosion-inhibiting sol-gel coating systems and methods

Patent metadata

Field	Value
Publication number	US-2016145443-A1
Application number	US-201414554335-A
Country	US
Kind code	A1
Filing date	Nov 26, 2014
Priority date	Nov 26, 2014
Publication date	May 26, 2016
Grant date	—

Abstract

Corrosion-inhibiting coating materials comprise a sol-gel and a corrosion-inhibiting compound with at least one disulfide group. The corrosion-inhibiting compound is contained within the sol-gel. Coated and/or laminated structures may include the corrosion-inhibiting coating materials on a metal substrate, and may include a secondary layer (e.g., a paint, etc.) adhered to the coating material opposite the metal substrate. Methods of forming a corrosion-inhibiting sol-gel comprise mixing organo-metallic compounds and the corrosion-inhibiting compound into a sol solution and incubating (e.g., reacting) the sol solution to form the corrosion-inhibiting sol-gel with the corrosion-inhibiting compound contained within the sol-gel. Generally, corrosion-inhibiting coating materials are hexavalent chromium free.

First claim

1 . A corrosion-inhibiting coating material bonded to a metal substrate, the coating material comprising:
a corrosion-inhibiting compound that includes at least one disulfide group; and a zirconium-based sol-gel bonded to the metal substrate; wherein the corrosion-inhibiting compound is contained within the zirconium-based sol-gel.

2 . The corrosion-inhibiting coating material of claim 1 , wherein the corrosion-inhibiting compound includes at least one thiol group.

3 . The corrosion-inhibiting coating material of claim 1 , wherein the corrosion-inhibiting compound is a polymer of 2,5-dimercapto-1,3,4-thiadiazole.

4 . The corrosion-inhibiting coating material of claim 1 , wherein the corrosion-inhibiting compound includes a thiolate group.

5 . A laminated structure comprising:
a metal substrate; and the corrosion-inhibiting coating material of claim 1 , bonded to the metal substrate.

6 . The laminated structure of claim 5 , wherein the metal substrate is an unplated aluminum alloy.

7 . The laminated structure of claim 5 , further comprising a secondary layer of organic material bonded to the corrosion-inhibiting coating material opposite the metal substrate.

8 . A method of forming a corrosion-inhibiting sol-gel, the method comprising:
mixing an organo-zirconate and a corrosion-inhibiting compound to form a sol solution, wherein the corrosion-inhibiting compound includes at least one disulfide group; and incubating the sol solution to form the corrosion-inhibiting sol-gel.

9 . The method of claim 8 , wherein the mixing includes mixing such that a weight fraction of the organo-zirconate in the sol solution is at least 0.5% and at most 5%.

10 . The method of claim 8 , wherein the mixing includes mixing such that a weight fraction of the corrosion-inhibiting compound in the sol solution is at least 0.1% and at most 10%.

11 . The method of claim 8 , wherein the mixing includes mixing an effective amount of the corrosion-inhibiting compound to protect a metal substrate, when bonded to the corrosion-inhibiting sol-gel, from significant corrosion after 24 hours of exposure to a spray of 5 wt. % of sodium chloride solution.

12 . The method of claim 8 , wherein the mixing includes dissolving the corrosion-inhibiting compound in a solvent before mixing with the organo-zirconate.

13 . The method of claim 12 , wherein the solvent includes at least one of an ether, a glycol ether, tetrahydrofuran, N-methyl-2-pyrrolidone, and dimethyl sulfoxide.

14 . The method of claim 8 , wherein the mixing includes introducing the corrosion-inhibiting compound as a powder to the organo-zirconate.

15 . The method of claim 8 , wherein the mixing includes mixing with a high-shear mixer.

16 . The method of claim 8 , wherein the corrosion-inhibiting compound includes at least one thiol group.

17 . The method of claim 8 , wherein the corrosion-inhibiting compound is a polymer of 2,5-dimercapto-1,3,4-thiadiazole.

18 . The method of claim 8 , further comprising coating a metal substrate with the corrosion-inhibiting sol-gel.

19 . The method of claim 18 , further comprising curing the corrosion-inhibiting sol-gel on the metal substrate.

20 . The method of claim 18 , further comprising applying a secondary layer of organic material to the corrosion-inhibiting sol-gel on the metal substrate.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick John
• Lawless Lawrence Michael
• Jackson Eileen

Classifications

• C09D5/08 Primary

  Anti-corrosive paints · CPC title

• C08L81/04

  Polysulfides · CPC title

• C23C18/00

  Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating · CPC title

• C08K5/56 Primary

  Organo-metallic compounds, i.e. organic compounds containing a metal-to-carbon bond · CPC title

• C09D165/00

  Coating compositions based on macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain (C09D107/00 - C09D157/00, C09D161/00 take precedence); Coating compositions based on derivatives of such polymers · CPC title