US4500610A — Corrosion resistant substrate with metallic under…

Claim 1

Independent Claim 101 words

A coated metal substrate having enhanced corrosion resistance and protected by a coating composite comprising a thin metallic undercoating layer of combined metals in metallic form at least one of which is selected from the group consisting of zinc, nickel, iron, chromium, aluminum and cobalt, and a heat-curable, substantially resin free, as well as phosphate free, topcoat layer from composition curable to a water resistance protective coating, said topcoat layer being free from particulate metals while containing above 10 milligrams per square foot of coated metallic undercoating of chromium, as chromium, in non-elemental form, said composition containing hexavalent-chromium-providing-substance in liquid medium.

Claim 2

Dependent Claim 101 words

A coated metal substrate having enhanced corrosion resistance and protected by a coating composite comprising a thin metallic undercoating layer of combined metals in metallic form at least one of which is selected from the group consisting of zinc, nickel, iron, chromium, aluminum and cobalt, and a heat-curable, substantially resin free, as well as phosphate free, topcoat layer from composition curable to a water resistance protective coating, said topcoat layer being free from particulate metals while containing above 10 milligrams per square foot of coated metallic undercoating of chromium, as chromium, in non-elemental form, said composition containing hexavalent-chromium-providing-substance in liquid medium.

Claim 3

Dependent Claim 28 words

The coated metal substrate of claim 1 wherein said substrate metal is selected from the group consisting of ferrous metal and zinc-, nickel-, cadmium-, cobalt-, and chromium-containing alloys.

Claim 4

Dependent Claim 16 words

The coated metal substrate of claim 1 wherein said metallic undercoating layer is in alloy form.

Claim 5

Dependent Claim 19 words

The coated metal substrate of claim 3 further characterized by having a zinc-containing alloy as said metallic undercoating layer.

Claim 6

Dependent Claim 32 words

The coated metal substrate of claim 4 wherein said metallic undercoating layer is selected from the group consisting of zinc-nickel alloy, zinc-iron alloy, zinc-aluminum alloy, zinc-cobalt alloy, zinc-aluminum-magnesium alloy and zinc-nickel-cobalt alloy.

Claim 7

Dependent Claim 20 words

The coated metal substrate of claim 1 further characterized by having less than about 25 microns thickness metallic undercoating layer.

Claim 8

Dependent Claim 31 words

The coated metal substrate of claim 1 wherein said metallic undercoating layer is present in an amount below about 15 microns thickness and contains greater than about 40 weight percent zinc.

Claim 9

Dependent Claim 25 words

The coated metal substrate of claim 7 wherein said metallic undercoating layer is present in an amount from about 0.2 to about 2 microns thickness.

Claim 10

Dependent Claim 47 words

The coated metal substrate of claim 1 wherein said substrate metal is ferrous metal, said ferrous metal is coated with a metallic pretreatment selected from the group consisting of nickel, cobalt, tin, copper and their mixtures where such exist and said metallic undercoating layer coats said pretreatment.

Claim 11

Dependent Claim 23 words

The coated metal substrate of claim 9 wherein said metallic pretreatment is present on the order of about one micron thickness or less.

Claim 12

Dependent Claim 39 words

The coated metal substrate of claim 1 wherein said water resistant topcoat layer contains more than about 15 milligrams per square foot of coated metallic undercoating of said chromium in non-elemental form and is established from aqueous-based, heat-curable, composition.

Claim 13

Dependent Claim 36 words

The coated metal substrate of claim 11 further characterized by said water resistant topcoat layer containing from about 20 to about 500 milligrams per square foot of coated metallic undercoating of said chromium in non-elemental form.

Claim 14

Dependent Claim 30 words

The coated metal substrate of claim 1 wherein said water resistant topcoat layer contains more than about 20 weight percent of said chromium, basis total topcoat chromium, as hexavalent chromium.

Claim 15

Dependent Claim 36 words

The coated metal substrate of claim 13 further characterized by having a water resistant topcoat layer containing more than about 20 weight percent but less than about 50 weight percent of said chromium in hexavalent form.

Claim 16

Dependent Claim 16 words

The coated metal substrate of claim 1 wherein said water resistant topcoat layer is further coated.

Claim 17

Dependent Claim 81 words

A coated metal substrate having enhanced corrosion resistance and protected by a coating composite comprising a thin metallic undercoating layer containing zinc and nickel in alloy form and a heat curable, substantially resin free, as well as phosphate free, topcoat layer from composition curable to a water resistant protective coating, said topcoat layer being free from particulate metals while containing above 10 milligrams per square foot of coated metallic undercoating of chromium, as chromium, said composition containing hexavalent-chromium-providing-substance in liquid medium.

Claim 18

Dependent Claim 81 words

A coated metal substrate having enhanced corrosion resistance and protected by a coating composite comprising a thin metallic undercoating layer containing zinc and nickel in alloy form and a heat curable, substantially resin free, as well as phosphate free, topcoat layer from composition curable to a water resistant protective coating, said topcoat layer being free from particulate metals while containing above 10 milligrams per square foot of coated metallic undercoating of chromium, as chromium, said composition containing hexavalent-chromium-providing-substance in liquid medium.

Claim 19

Dependent Claim 28 words

The coated metal substrate of claim 16 wherein said substrate metal is selected from the group consisting of ferrous metal and zinc-, nickel-, cadmium-, cobalt-, and chromium-containing alloys.

Claim 20

Dependent Claim 17 words

The coated metal substrate of claim 16 wherein said metallic undercoating layer is an electrodeposited alloy coating.

Claim 21

Dependent Claim 24 words

The coated metal substrate of claim 16 wherein said metallic undercoating layer is selected from the group consisting of zinc-nickel alloy and zinc-nickel-cobalt alloy.

Claim 22

Dependent Claim 22 words

The coated metal substrate of claim 16 further characterized by having less than about 25 microns thickness of zinc-nickel alloy undercoating layer.

Claim 23

Dependent Claim 24 words

The coated metal substrate of claim 20 further characterized by having from about 0.2 to about 2 microns thickness of zinc-nickel alloy undercoating layer.

Claim 24

Dependent Claim 34 words

The coated metal substrate of claim 16 wherein the metals present in said metallic undercoating layer in other than trace amounts, are less than about 25 weight percent nickel and a balance of zinc.

Claim 25

Dependent Claim 35 words

The coated metal substrate of claim 22 wherein the metals of said metallic undercoating layer in greater than trace amounts are from about 5 to about 20 weight percent nickel and a balance of zinc.

Claim 26

Dependent Claim 33 words

The coated metal substrate of claim 16 wherein said substrate metal is ferrous metal, said ferrous metal is coated with a metallic nickel pretreatment and said metallic undercoating layer coats said nickel pretreatment.

Claim 27

Dependent Claim 24 words

The coated metal substrate of claim 24 wherein said metallic nickel pretreatment is present on the order of about one micron thickness or less.

Claim 28

Dependent Claim 38 words

The coated metal substrate of claim 16 wherein said water resistant topcoat layer contains more than about 15 milligrams per square foot of coated metallic undercoating of chromium in non-elemental form and is established from aqueous-based, heat-curable composition.

Claim 29

Dependent Claim 34 words

The coated metal substrate of claim 26 wherein said water resistant topcoating layer contains from about 20 to about 500 milligrams per square foot of coated metallic undercoating of said chromium in non-elemental form.

Claim 30

Dependent Claim 30 words

The coated metal substrate of claim 16 wherein said water resistant topcoat layer contains more than about 20 weight percent of said chromium, basis total topcoat chromium, as hexavalent chromium.

Claim 31

Dependent Claim 33 words

The coated metal substrate of claim 28 wherein said water resistant topcoat layer contains more than about 20 weight percent but less than about 50 weight percent of said chromium in hexavalent form.

Claim 32

Dependent Claim 16 words

The coated metal substrate of claim 16 wherein said water resistant topcoat layer is further coated.

Claim 33

Dependent Claim 115 words

A coated metal article in sheet form having on one or both faces of said formed article a thin metallic undercoating layer of combined metals in metallic form at least one of which is selected from the group consisting of zinc, nickel, iron, chromium, aluminum and cobalt, while further having on one or both faces of said formed article a heat curable, substantially resin free, as well as phosphate free, topcoat layer from composition curable to a water resistant protective coating, said topcoat layer being free from particulate metals while containing about 10 milligrams per square foot of coated metallic undercoating of chromium, as chromium, in non-elemental form, said composition containing hexavalent-chromium-providing-substance in liquid medium.

Claim 34

Dependent Claim 115 words

A coated metal article in sheet form having on one or both faces of said formed article a thin metallic undercoating layer of combined metals in metallic form at least one of which is selected from the group consisting of zinc, nickel, iron, chromium, aluminum and cobalt, while further having on one or both faces of said formed article a heat curable, substantially resin free, as well as phosphate free, topcoat layer from composition curable to a water resistant protective coating, said topcoat layer being free from particulate metals while containing about 10 milligrams per square foot of coated metallic undercoating of chromium, as chromium, in non-elemental form, said composition containing hexavalent-chromium-providing-substance in liquid medium.

Claim 35

Dependent Claim 18 words

The coated metal article of claim 31 further characterized by being a coated steel sheet in coil form.

Claim 36

Dependent Claim 41 words

The coated metal article of claim 31 wherein said metallic undercoating is an electrodeposited zinc and nickel alloy coating and said topcoating contains more than about 15 milligrams per square foot of coated substrate of chromium, as chromium, in non-elemental form.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1988-02-19	1988-08-20	1989-02-19	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1992-02-19	1992-08-20	1993-02-19	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1996-02-19	1996-08-20	1997-02-19	$7700.00	Window Closed / Lapsed

Corrosion resistant substrate with metallic undercoat and chromium topcoat

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