Soluble corrosion resistant sol-gel

Patent metadata

Field	Value
Publication number	US-2023416539-A1
Application number	US-202318460172-A
Country	US
Kind code	A1
Filing date	Sep 1, 2023
Priority date	Feb 2, 2018
Publication date	Dec 28, 2023
Grant date	—

Abstract

Aspects described herein generally relate to a sol-gel that is the reaction product of an organosilane, a metal alkoxide, an acid, and a thio-lanthanide salt having a solubility of about 1 gram or greater per gram of sol-gel at 23° C. The thio-lanthanide salt includes a cation and a thio-ligand. The cation can be lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, yttrium, cobalt, calcium, strontium, barium, and zirconium. In another aspect, a component, such as a vehicle component, includes a metal substrate and a sol-gel disposed on the metal substrate. Methods can include forming a sol-gel by mixing a metal alkoxide and an acid to form a first mixture; mixing with the first mixture an organosilane to form a second mixture; and mixing with the second mixture a lanthanide salt to form a third mixture.

First claim

What is claimed is:

1 . A method of forming a sol-gel, comprising:
mixing a metal alkoxide and an acid to form a first mixture, wherein the molar ratio of acid to metal alkoxide is from about 1:1 to about 40:1; mixing with the first mixture an organosilane to form a second mixture, wherein the organosilane is represented by Formula (II):

wherein R is selected from the group consisting of alkyl, cycloalkyl, aryl, arylether, poly(ethylene glycol), and poly(propylene glycol); and
mixing a thio-lanthanide salt with the second mixture to form a third mixture.

2 . The method of claim 1 , further comprising depositing the first mixture, the second mixture, or the third mixture onto a metal substrate.

3 . The method of claim 2 , further comprising curing the third mixture.

4 . The method of claim 3 , further comprising cleaning the metal substrate by degreasing, alkaline washing, chemical etching, chemically deoxidizing, and/or mechanically deoxidizing the metal surface prior to depositing.

5 . The method of claim 3 , further comprising depositing a secondary layer onto the sol-gel.

6 . The method of claim 5 , wherein the secondary layer is an epoxy coating or urethane coating.

7 . The method of claim 1 , wherein the molar ratio of acid to metal alkoxide is about 3:1 to about 8:1.

8 . The method of claim 1 , wherein the second mixture is a binder.

9 . The method of claim 8 , wherein the weight fraction of binder in the sol-gel is about 0.3 wt % to about 50 wt %.

10 . The method of claim 9 , wherein the weight ratio of thio-lanthanide salt to binder is about 1:1 to about 5:1.

11 . The method of claim 1 , wherein the sol-gel comprises about 50 wt % or greater of water.

12 . The method of claim 2 , wherein depositing comprises any one or more methods of depositing the first mixture, the second mixture, or the third mixture onto a metal substrate, selected from the group consisting of spraying, immersing, brushing, or wiping.

13 . The method of claim 12 , wherein the method of depositing is spraying, which can include any one or more suitable forms of spaying selected from the group consisting of spraying with a spray gun, a high-volume, low-pressure spray gun, or a hand pump sprayer.

14 . The method of claim 1 , further comprising incubating the first mixture, the second mixture, or the third mixture for about 1 minute to about 60 minutes at a temperature of about 30 ° C. to about 50 ° C.

15 . A component, comprising:
a sol-gel coating disposed on a metal substrate, the sol-gel coating further comprising:
about 50 wt % or greater of water;
about 3 wt % to about 10 wt % of a compound that is a thio-lanthanide (III) salt, wherein the thio-lanthanide (III) salt comprises a triazole thiol ligand and a cation selected from cerium, praseodymium, or yttrium; and
a binder comprising:
an organosilane represented by Formula (II):

wherein R is selected from the group consisting of alkyl, cycloalkyl, aryl, arylether, poly(ethylene glycol), and poly(propylene glycol);
a zirconium (IV) tetraalkoxide; and
acetic acid;
wherein:
a molar ratio of the acetic acid to the zirconium (IV) tetraalkoxide is from about 1:1 to about 40:1,
a weight fraction of the binder in the sol-gel is about 0.3 wt % to about 50 wt %;

a weight ratio of the thio-lanthanide (III) salt to the binder is from about to about 5:1; and
the thio-lanthanide (III) salt has a solubility in the sol-gel such that at least 1 g of thio-lanthanide (III) salt is soluble in 1 g of sol-sel.

16 . The component of claim 15 , wherein the sol-gel coating has a thickness of about 1 μm to about 500 nm.

17 . The component of claim 15 , wherein the sol-gel coating has a thickness of about 5 μm to about 100 nm.

18 . The component of claim 15 , wherein the sol-gel coating has a thickness of about 10 μm to about 100 μm.

19 . The component of claim 15 , wherein the metal substrate is selected from aluminum, aluminum alloy, nickel, iron, iron alloy, steel, titanium, titanium alloy, copper, copper alloy, and mixtures thereof.

20 . The component of claim 15 , wherein the component is a vehicle component selected from an auxiliary power unit, a nose of an aircraft, a fuel tank, a tail cone, a panel, a coated lap joint between two or more panels, a wing-to-fuselage assembly, a structural aircraft composite, a fuselage body-joint, a wing rib-to-skin joint, and an internal component.

Assignees

• Boeing Co
• Commw Scient Ind Res Org

Inventors

• Schuette Waynie M
• Kinlen Patrick J
• White Paul Andrew

Classifications

• C09D5/086 Primary

  Organic or non-macromolecular compounds · CPC title

• C09D183/14

  in which at least two but not all the silicon atoms are connected by linkages other than oxygen atoms (C09D183/10 takes precedence) · CPC title

• C08G77/58 Primary

  Metal-containing linkages · CPC title

• C09D7/60

  non-macromolecular (C09D7/41-C09D7/48 take precedence) · CPC title

• C09D5/082

  characterised by the anti-corrosive pigment · CPC title