Articles having thermoset coatings and coating methods

{
  "publication_number": "US9738792B2",
  "country": "US",
  "kind": "B2",
  "title": "Articles having thermoset coatings and coating methods",
  "abstract": "A method to prevent corrosion of a susceptible article of a two-article system, in which first and second articles of the two-article system have surfaces facing one another and in which the two articles have different anodic indices includes applying a coating material to the surface of the first article and curing the coating material on the surface of the first article. The method further includes contacting and securing the surface of the first article with the surface of the second article. The two articles exhibit substantially no corrosion following exposure to a corrosive environment under standard GMW17026 for a 15 year simulated test.",
  "claims": [
    "1. A method to prevent corrosion of a susceptible article of a two-article system, in which first and second articles of the two-article system have surfaces facing one another and in which the two articles have different anodic indices, the method comprising: applying a coating material to the surface of the first article; curing the coating material on the surface of the first article; and contacting and securing the surface of the first article with the surface of the second article, wherein the two articles exhibit substantially no corrosion following exposure to a corrosive environment under standard GMW17026 after a 15 year simulated test.",
    "2. The method of claim 1 wherein the coating material is a thermoset material.",
    "3. The method of claim 2 wherein the thermoset material is an epoxy material that cross links during coating to form a cross-linked epoxy coating.",
    "4. The method of claim 3 wherein the epoxy material is a fusion bond epoxy material.",
    "5. The method of claim 3 wherein the epoxy material comprises a curing agent.",
    "6. The method of claim 5 wherein the curing agent comprises one or more of more amines, anhydrides, acids, phenols, alcohols and thiols.",
    "7. The method of claim 3 wherein the wherein the epoxy material comprises one or more of a filler and a pigment.",
    "8. The method of claim 3 wherein the epoxy material cures in approximately thirty seconds or less when subjected to a temperature of about 400 to 450 degrees Fahrenheit to form the cross-linked epoxy coating.",
    "9. The method of claim 1 wherein the coating material is applied as a powder.",
    "10. The method of claim 9 wherein the powder is sprayed onto the article.",
    "11. The method of claim 10 wherein the powder has a charge applied thereto.",
    "12. The method of claim 1 wherein the coating material comprises a first coating material and a second coating material and wherein the first coating material is fully cured to form a first cured layer and the second coating material is applied onto the first cured layer.",
    "13. The method of claim 12 wherein the second coating material is a thermoset material.",
    "14. The method of claim 13 wherein the first coating material is a fast curing material and the second coating material cures at a slower rate than the first coating material.",
    "15. The method of claim 12 wherein the second coating material is a lubricant.",
    "16. The method of claim 15 wherein the lubricant is one or more of a polyethylene wax, a paraffin wax, a carnauba wax, and a solid lubricant.",
    "17. The method of claim 16 wherein the solid lubricant is one or more of molybdenum disulfide and a fluoropolymer.",
    "18. The method of claim 1 wherein the coating material, when cured, has a substantially uniform thickness of about 0.005 to 0.0035 inches.",
    "19. The method of claim 18 wherein the thickness is about 0.0015 inches.",
    "20. The method of claim 1 wherein the first coating material is an oxide-based ceramic material.",
    "21. The method of claim 1 wherein the curing is heat curing.",
    "22. The method of claim 21 wherein the heat curing is induction heat curing and includes the application of a magnetic field.",
    "23. The method of claim 1 wherein the article to which the first coating material is applied is preheated prior to application of the first coating material.",
    "24. The method of claim 1 wherein the first and second articles are dissimilar metals.",
    "25. The method of claim 1 wherein one of the first and second articles is a non-metal.",
    "26. The method of claim 24 wherein when the cured coating material is present on at least a head of a steel bolt mounted to a magnesium coupon, the magnesium coupon exhibits less than about 3% of pitting compared to an uncoated steel bolt on the magnesium coupon after a 15 year simulated test under test procedure GMW17026.",
    "27. The method of claim 1 wherein the first article has an anodic index that is greater than the second article.",
    "28. The method of claim 1 wherein the first article comprises iron or an iron alloy.",
    "29. The method of claim 1 wherein the second article comprises magnesium or a magnesium alloy.",
    "30. The method of claim 1 wherein the second article comprises aluminum or an aluminum alloy.",
    "31. The method of claim 1 wherein the first article is a male-part fastener.",
    "32. The method of claim 31 wherein the male-part fastener is a bolt or screw.",
    "33. The method of claim 31 wherein the bolt exhibits a tension loss of no more than about 25% when heated to a temperature of 125° C. for a period of 800 hours.",
    "34. A two-article system in which first and second articles of the two-article system have surfaces facing one another and in which the two articles have different anodic indices, the surface of the first article comprising a coating layer formed by curing a coating material on the surface of the first article, and the surface of the first article in contact and secured with the surface of the second article, wherein the two articles exhibit substantially no corrosion following exposure to a corrosive environment under standard GMW17026 after a 15 year simulated test.",
    "35. The system of claim 34 wherein the coating material is a thermoset material.",
    "36. The system of claim 35 wherein the thermoset material is a cross-linked epoxy coating.",
    "37. The system of claim 36 wherein the epoxy material is a fusion bond epoxy material.",
    "38. The system of claim 36 wherein the epoxy material comprises a curing agent.",
    "39. The system of claim 38 wherein the curing agent comprises one or more of more amines, anhydrides, acids, phenols, alcohols and thiols.",
    "40. The system of claim 36 wherein the epoxy material comprises one or more of a filler and a pigment.",
    "41. The system of claim 36 wherein the epoxy material cures in approximately thirty seconds or less when subjected to a temperature of about 400 to 450 degrees Fahrenheit to form the cross-linked epoxy coating.",
    "42. The system of claim 34 wherein the coating material comprises a first coating material and a second coating material, and wherein the first coating material is fully cured to form a first cured layer, and the second coating material is applied onto the first cured layer to form the coating material.",
    "43. The system of claim 42 wherein the second coating material is a thermoset material.",
    "44. The system of claim 43 wherein the first coating material is a fast curing material and the second coating material cures at a slower rate than the first coating material.",
    "45. The system of claim 42 wherein the second coating material is a lubricant.",
    "46. The system of claim 45 wherein the lubricant is one or more of a polyethylene wax, a paraffin wax, a carnauba wax, and a solid lubricant.",
    "47. The system of claim 46 wherein the solid lubricant is one or more of molybdenum disulfide and a fluoropolymer.",
    "48. The system of claim 34 wherein the coating material, when cured, has a substantially uniform thickness of about 0.005 to 0.035 inches.",
    "49. The system of claim 48 wherein the thickness is about 0.001 to 0.0025 inches.",
    "50. The system of claim 34 wherein the surface of the first article comprises an oxide-based ceramic material to which the coating material is applied.",
    "51. The system of claim 34 wherein the first and second articles are dissimilar metals.",
    "52. The system of claim 34 wherein one of the first and second articles is a non-metal.",
    "53. The system of claim 34 wherein the first article is a steel bolt and the second article is formed from a metal having a lesser anodic index.",
    "54. The system of claim 53 wherein the second article is formed from magnesium and wherein the cured coating material is present on at least a head of the steel bolt, and wherein when mounted to a magnesium coupon, the magnesium coupon exhibits less than about 3% of pitting of a comparable uncoated steel bolt on the magnesium coupon after a 15 year simulated test under test procedure GMW17026.",
    "55. The system of claim 34 wherein the first article has an anodic index that is greater than the second article.",
    "56. The system of claim 34 wherein the first article comprises iron or an iron alloy.",
    "57. The system of claim 34 wherein the second article comprises magnesium or a magnesium alloy.",
    "58. The system of claim 34 wherein the second article comprises aluminum or an aluminum alloy.",
    "59. The system of claim 34 wherein the first article is a male-part fastener.",
    "60. The system of claim 59 wherein the male-part fastener is a bolt or screw.",
    "61. The system of claim 59 wherein the screw exhibits a tension loss of no more than about 25% when heated to a temperature of 125° C. for a period of 800 hours.",
    "62. The system of claim 34 wherein the first article is a steel bolt and wherein the coating layer is present on at least a head and an underside of the head of the steel bolt."
  ],
  "description_excerpt": "Certain aspects of this disclosure relate to articles and/or assemblies having coated components or features, and processes for coating such articles. In particular, certain aspects of the disclosure relate to a metal article at least partially covered with one or more thermoset coatings and/or an inorganic coating capable of preventing galvanic corrosion from occurring when the article is in contact with a dissimilar metal or other material in the presence of an electrolyte, assemblies having such an article, and processes for producing such articles.\n\nThere are many different types of corrosion. In general, corrosion is the conversion of a material, for example, a metal, to a more stable form. There are, however, two major types of corrosion: general or uniform attack corrosion; and galvanic corrosion. General or uniform attack corrosion can occur, for example, when iron is in a wet or damp environment and it corrodes, forming iron oxide in the process.\n\nGalvanic corrosion, on the other hand, occurs when two materials having different anodic indices or electro-potentials are in contact with, or close proximity to, one another in the presence of an electrolyte. The electro-potential difference produces electron flow between the materials. In such a system, one of the materials is more active (or less noble) and serves as an anode and the other material is less active (or more noble) and serves as a cathode. The anode corrodes at an accelerated rate, while the cathode corrodes at a lesser rate.",
  "cpc": [
    "C09D 5/08",
    "B05D 1/12",
    "C09D 163/00",
    "C23F 11/12",
    "F16B 33/00",
    "F16B 33/008",
    "F16B 33/06"
  ],
  "ipc": [
    "B05D 1/12",
    "C09D 163/00",
    "C09D 5/08",
    "C23F 11/12",
    "F16B 33/00",
    "F16B 33/06",
    "F16B 35/04"
  ],
  "assignees": [
    "Nylok LLC"
  ],
  "inventors": [
    "Jeffrey M. Stupar",
    "Franco A. Cisternino",
    "Eugene D. Sessa",
    "Robin F. Monahan"
  ],
  "filing_date": "2016-02-02",
  "publication_date": "2017-08-22",
  "grant_date": "2017-08-22",
  "priority_date": "2015-02-03",
  "application_number": "US-201615013294-A",
  "family_id": "56552847",
  "cited_by_count": 10,
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}