Process for Coating Metal Surfaces With Synthetic Resins

The present invention relates to a process for coating of metal surfaces with synthetic resins, in which the metal surfaces are subjected to a special pre-treatment by high energy rays before applying the synthetic resin.

It is known that in vapour deposition processes, for example, an extremely thin layer of metal is vapor-deposited on a substrate in vacuo. In such processes, the surface of the substrate is bombarded, before the vapor deposition, with ions and electrons from a gas discharge (that is to say, exposed to a glow discharge) or exposed to pure electron bombardment in vacuo, in order to improve the adhesion of the material being vapor-deposited. For example, the vapor-deposited metal or a vapor-deposited layer of a dielectric adheres substantially better to a surface pretreated in this way than without such pre-treatment.

Further, it is known that in coating metal sheets with synthetic resins, the problem of how to improve the adhesion of the synthetic resins to the surfaces of the metal sheets constantly recurs. In order to solve this problem work has been carried out in particular to improve the lacquers, or the plastic powder compositions, themselves. Of course, endeavours have also been made to achieve an improvement in the adhesion of the synthetic resins to the metal surfaces by subjecting the metal surfaces to a chemical and/or mechanical pre-treatment. Approaches known in this field are, for example, cleaning with trichloraethylene, and phosphatising or chromatising the metal surfaces by dipping the metal articles into appropriate baths, with subsequent rinsing. However, these baths entail considerable effort. In particular, their consumption of rinsing water, and the effluent contamination resulting therefrom, represent a major pollution of the environment. For example, the coating of metal surfaces with synthetic resin powders, in which no solvents are required, would be very advantageous from an environmental point of view if the objectionable pre-treatment stages in the various baths were not necessary.

It is, therefore, an object of the present invention to develop a process for coating metal surfaces with synthetic resin, in which (1) the synthetic resin adheres at least as well as in the case of the conventional coating processes; (2) the metal surface has been subjected to a chemical and/or mechanical pre-treatment, and (3) (new process) the expensive chemical and/or mechanical pre-treatments are replaced by a simple, clean pre-treatment which does not pollute the environment.

This and other objects have been achieved by exposing the metal surfaces, prior to their coating with synthetic resin, to high energy radiation, such as, for example, an electron beam and/or an ion beam, in the presence of an organic substance and/or of an organosilicon-oxygen compound (e.g., a silicone) which is present on the metal surface in the form of a thin film or is in contact, in the form of a gas, with the metal surface.

In fact it has been found, surprisingly, that substantially better adhesion of the synthetic resin to the metal surface is achieved if the metal surface is exposed to the high energy radiation in the presence of organic substances and/or organosilicon-oxygen compounds. Evidently, this produces a contamination layer which can consist, for example, of hydrocarbon molecules, and which adheres very firmly to the metal surface. Detaching this layer by means of the customary chemical agents is virtually impossible. Mechanical methods have to be employed for this purpose.

The only FIGURE of the drawing is a side sectional view of the apparatus used for carrying out the process according to the invention.

Thus, the drawing shows schematically, in section, the scanner 1, the electron beam outlet window 2 and the window flange 5 of an electron accelerator. The electrons arriving under acceleration in the evacuated scanner 1 issue into the air through the electron beam outlet window 2 and act on the material 3 being irradiated. Material 3 being irradiated is moved by means of a conveying device 4 at right angles to the scanning direction and at right angles to the electron beam. The material being irradiated can be, for example, cold-rolled steel sheet, aluminum sheet, stainless steel sheet, galvanised (iron) sheet, tinplate and the like, covered with a very thin film of mineral oil for corrosion protection. Of course, these metal sheets can also be irradiated at atmospheric pressure under a gaseous organic substance, for example by blowing a hydrocarbon against the metal sheets at the irradiation station. It is also possible to carry out both the process variants described above in vacuo, for example by introducing the plane strip of metal sheet into a vacuum chamber through so-called pressure locks. In that case, electrons with an acceleration voltage of only 20 kV - 60 kV are required for the irradiation.

Organic compounds which can be used are, in particular, mineral oils and gaseous hydrocarbons. Of course, fatty oils, fats and waxes, as well as all liquid and gaseous derivatives of the aliphatic and aromatic hydrocarbons, including heterocyclic compounds, can also be used. As silicones it is in particular possible to use the oily silicones. It should be noted, however, as a fundamental principle, that according to the invention it is also possible to employ, instead of the organic and/or silicone compounds, such compounds of other elements as decompose under the influence of the high energy radiation to form a contamination layer on the metal surface which is to be coated.

As already mentioned, the coating of the metal surface which has been pre-treated according to the invention is carried out in the usual manner with plastic powders or plastic lacquer preparations. Preferably, an epoxide resin powder, especially having a particle size of approximately 12 to 50 .mu., is employed according to the invention.

Furthermore, it should be pointed out at this stage that according to the invention it has also been found, surprisingly, that the irradiation with high energy rays, especially with electron beams and/or ion beams, of steel surfaces which are coated with a thin film of an organic or silicone compound for temporary corrosion protection, results in lengthening the duration of the temporary corrosion protection. For example, 20 sample sheets were cut out of a cold-rolled (steel) sheet which is coated, by the sheet manufacturer, with a thin film of oil (deep drawing oil) to afford temporary corrosion protection. 10 of these "oiled" sample sheets were irradiated with electrons, whilst 10 were not. All 20 samples were then suspended for several weeks in a bath of tap water. The non-irradiated sample sheets had already rusted heavily after this period, while the irradiated sample sheets merely showed small patches of rust in isolated places. As a result of this treatment according to the invention, the temporary corrosion protection of "oiled" metal sheets can be extended from approx. 4 weeks to approx. 4 months.

The examples which follow serve to illustrate the invention without, however, restricting it thereto.

A cold-rolled steel sheet covered with a thin film of a deep-drawing oil is mechanically cleaned to remove dust and other contaminations, then bent to form a refrigerator cladding component, folded and then irradiated with electrons from an electron accelerator which has an acceleration voltage of 300 kV, an electron current of 50 mA and a scanner length of 1.30 m. The speed of advance of the bent and folded component which is to be irradiated is 6 m per minute. The electron accelerator, with scanner, is set up horizontal and the components are suspended and passed in front of the accelerator. The reach of the electrons in air is so great that even surfaces which run parallel to the electron beam receive a sufficient dose. Any areas which may lie in the shadow of the electron beam can also be irradiated, by fixing a lead reflector on which the electrons are reflected.

The epoxide resin powder is then applied electrostatically to the components pre-treated in this way and is sintered, and cured, in the course of 5 minutes at 200.degree. C. in a tunnel oven. The resulting coating shows excellent adhesion.

A continuous sheet of aluminum which is intended to be used for facade cladding is introduced through a pressure lock into a chamber which is under partial vacuum, and is irradiated with electrons. At the irradiation station, gaseous benzene is blown onto the metal sheet surface. Since flat sheet material is concerned, an electron accelerator with the following data is adequate: acceleration voltage 150 kV, electron beam current 100 mA, scanner length 1.30 m. The speed of travel of the aluminum sheet is 20 m per minute. The continuous aluminum sheet passes horizontally below the vertical electron accelerator. To irradiate the rear face (if this is also to be coated) it is possible to use a second electron accelerator with the same characteristic data.

The epoxide resin powder is applied electrostatically to the continuous metal sheet which has been pre-treated in this way and is sintered, and cured, in the course of 5 minutes in a tunnel oven at 200.degree. C. The resulting coating again shows excellent adhesion.