Metal surface treatment composition, metal surface treatment method, and galvanized steel plate

Abstract

It is an object of the present invention to provide a metal surface treatment composition and a metal surface treatment method superior in stability, which can apply a good chemical conversion treatment to a galvanized steel plate without requiring a burden of waste water treatment, and a galvanized steel plate superior in a rust-preventive property and adhesion, which is obtained by such a metal surface treatment method. A metal surface treatment composition comprising niobium oxide colloidal particles, wherein the niobium oxide colloidal particles are derived from a niobium oxide sol which is stabilized by containing citric acid or salts thereof in an amount of 0.02 to 1.0 by a mole ratio relative to Nb.

Description

TECHNICAL FIELD

The present invention relates to a metal surface treatment composition, a metal surface treatment method and a galvanized steel plate.

BACKGROUND ART

Galvanized steel plates, to which zinc plating or zinc alloy plating is applied, are used as steel materials having the high corrosion resistance. In such galvanized steel plates, a zinc plating layer is oxidized through contact with air to form white color rust. Therefore, it is necessary to prevent oxidation by applying surface treatment. In some applications, galvanized steel plates are used without being coated after being processed. In such a case, it is important that the galvanized steel plate has a rust-preventive property in an uncoated condition.

As such treatment, there is known chromate-treatment using a chromium compound. When chromate-treatment is applied, the formation of white color rust is prevented and a very good galvanized steel plate can be obtained. However, since the waste water containing a chromium compound requires a great deal of burden for the disposal, a method of performing chemical conversion treatment with a chromate-free treatment agent not using chromium is studied.

As such a chromate-free treatment agent, there are disclosed metal surface treatment agents for galvanized steel plates, which contain metal salt compounds (cf. Japanese Kokai Publication Hei-9-241856, Japanese Kokai Publication 2001-172771 and Japanese Kokai Publication 2001-247977, for instance). However, galvanized steel plates, surface treated with such the treatment agents, did not have sufficient properties of a rust-preventive property, adhesion to a film and the like.

In addition, a chemical conversion treatment solution for galvanized steel plates, which contains oxyacid salts of metals selected from molybdenum, vanadium, tungsten, niobium and tantalum, manganese compounds, titanium compounds and phosphoric acid or phosphates, is disclosed (cf. Japanese Kokai Publication 2002-105659, for instance). However, in such a chemical conversion treatment solution for galvanized steel plates, it is necessary to use a manganese compound. Since the manganese compound also requires a great deal of burden for the disposal of its waste water, it is preferred not to use it.

In addition, as a rust-preventive component used for a metal surface treatment composition, water-dispersible silica is used. However, when the water-dispersible silica is used alone, it did not have an adequate rust-preventive property and the metal surface treatment composition could not attain an adequate rust-preventive property in providing the rust-preventive property for such a galvanized steel plate.

SUMMARY OF THE INVENTION

In view of the above circumstances, it is an object of the present invention to provide a metal surface treatment composition and a metal surface treatment method superior in stability, which can apply a good chemical conversion treatment to a galvanized steel plate without requiring a burden of waste water treatment, and a galvanized steel plate superior in a rust-preventive property and adhesion, which is obtained by such a metal surface treatment method.

The present invention provides a metal surface treatment composition comprising niobium oxide colloidal particles,

• • wherein the niobium oxide colloidal particles are derived from a niobium oxide sol which is stabilized by containing citric acid or salts thereof in an amount of 0.02 to 1.0 by a mole ratio relative to Nb.

Preferably, the niobium oxide colloidal particle has an average particle diameter of 100 nm or less.

Preferably, the niobium oxide colloidal particle has a content of 1 mass % or more relative to the total nonvolatile matter in the metal surface treatment composition when Nb contained in the niobium oxide colloidal particle is converted to equivalent Nb₂O₅.

Preferably, the metal surface treatment composition comprises

• • a water-borne resin in an amount of 5 to 90 mass % relative to the total nonvolatile matter in the metal surface treatment composition.

Preferably, the water-borne resin is at least one kind selected from the group consisting of acrylic resin, polyolefinic resin, polyurethane resin, epoxy resin, olefin-acrylic acid copolymer resin, phenolic resin, polyester resin, alkyd resin, melamine resin, polycarbonate resin, polyacrylic acid and copolymers or block polymers thereof.

Preferably, the metal surface treatment composition comprises

• • water-dispersible silica in an amount of 80 mass % or less relative to the total nonvolatile matter in the metal surface treatment composition.

Preferably, the metal surface treatment composition comprises

• • at least one compound selected from the group consisting of vanadium compounds, zirconium compounds and titanium compounds in an amount of 0.1 to 30 mass % on the V, Zr or Ti basis relative to the total nonvolatile matter in the metal surface treatment composition.

Preferably, the metal surface treatment composition comprises

• • a silane coupling agent in an amount of 0.5 to 30 mass % relative to the total nonvolatile matter in the metal surface treatment composition.

Preferably, the metal surface treatment composition comprises

• • a phosphate compound in an amount of 0.1 to20 mass % relative to the total nonvolatile matter in the metal surface treatment composition.

Preferably, in the metal surface treatment composition, pH is 6 to 11.

Preferably, in the metal surface treatment composition, the concentration of the nonvolatile matter is 3 to 50 mass % on the mass of the nonvolatile matter basis.

The present invention provides a metal surface treatment method comprising

• • applying surface treatment to a galvanized steel plate with the metal surface treatment composition, thereby forming a coat thereof.

The present invention provides a coated galvanized steel plate obtained by the metal surface treatment method.

DISCLOSURE OF THE INVENTION

Hereinafter, the present invention will be described in detail.

A metal surface treatment composition of the present invention comprises a niobium oxide sol which is formed by dispersing niobium oxide colloidal particles highly stabilized with citric acid or salts thereof in an aqueous medium. The niobium oxide colloidal particles more preferably have a smaller average particle diameter because when the average particle diameter is small, a more stable and dense treated coat of the niobium oxide is formed and therefore the niobium oxide colloidal particles can provide a rust-preventive property stably for an article to be treated. In addition, the metal surface treatment composition does not need to contain components, requiring a burden of waste water treatment, such as chromium and manganese.

The niobium oxide colloidal particle to be used in the present invention refers to one which is formed by niobium oxide dispersing in fine particle form in water. For example, a substance, which is present in intermediate region between niobium hydroxide and niobium oxide and becomes an amorphous state without becoming complete niobium oxide, may be used.

The metal surface treatment composition of the present invention can be prepared by using a niobium oxide sol made by a method publicly known. The niobium oxide sol is not particularly limited, and for example, a substance made by a publicly known method, which is described in Japanese Patent No. 2849799 and the like, can be given. Further, niobium oxide sol made by Taki Chemical Co., Ltd. may be employed.

An example of a method of producing the niobium oxide sol may include a method in which niobium oxide is dissolved in hydrofluoric acid and the dissolved solution is added to aqueous ammonia and then the mixture is filtered and washed to yield niobium hydroxide in slurry form, and oxalate dihydrate is added to the slurry of niobium hydroxide and then water is added, and after a uniform solution composed of niobium oxide colloidal particles is obtained by allowing the reaction of this mixture to proceed under stirring in a condition of refluxing, then citric acid or salt thereof was added to the solution and the resulting mixture is stirred. In order to adjust the obtained niobium oxide sol to a desired level of pH, a basic compound such as ammonia may be added to the sol as required. In order to identify that the reaction has been completed, that is, a uniform solution of niobium oxide colloidal particles has been obtained before adding citric acid, color of the slurry solution can be utilized and when the slurry exhibits blue color, it is assumed to be in a uniform state.

The niobium oxide sol, which can be used for the metal surface treatment composition of the present invention, is formed by making the niobium oxide sol solution stabilized with oxalic acid further contain citric acid and highly stabilizing it. The metal surface treatment composition of the present invention can be prepared by diluting the niobium oxide sol to a required concentration or by adding another component as required and is stable over the long term without causing thickening, gelation or precipitation even after the preparation. An essential point is that the niobium oxide sol to be used in the metal surface treatment composition of the present invention is in a state highly stabilized with citric acid or salt thereof, and an amount of oxalic acid or salt thereof, which is mixed in producing the niobium oxide sol, is not particularly limited. The niobium oxide sol is preferred in that thereby, the stability of niobium oxide colloidal particles is not degraded in being mixed with another components, which is contained in the metal surface treatment composition of the present invention, such as a water-borne resin, water-dispersible silica, vanadium compounds, zirconium compounds, titanium compounds, silane coupling agents and the phosphate compounds.

An amount of citric acid or salts thereof added to the metal surface treatment composition of the present invention is preferably within a range of 0.02 (lower limit) to 1.0 (upper limit) by a mole ratio relative to Nb in the metal surface treatment composition. When the amount of citric acid or salts thereof to be added is less than 0.02 by a mole ratio, the stability in adding another components becomes insufficient, and when it exceeds 1.0 by a mole ratio, it is not possible any longer to attain an effect of stabilization corresponding to the amount to be added and hence it is uneconomical.

The niobium oxide colloidal particles preferably have an average particle diameter of 100 nm or less. When the average particle diameter is small, the niobium oxide colloidal particles can provide a rust-preventive property stably for an article to be treated because a more stable and dense treated coat of the niobium oxide is formed. The average particle diameter of the niobium oxide colloidal particles can be measured using a particle size distribution analyzer based on dynamic scattering light, for example, NICOMP MODEL-370 type (manufactured by PACIFIC SCIENTIFIC INSTRUMENTS Co.).

The metal surface treatment composition of the present invention preferably contains the niobium oxide colloidal particles in an amount of 1 mass % or more relative to the total nonvolatile matter in the metal surface treatment composition when Nb in the colloidal particles is converted to equivalent Nb₂O₅. When the content is less than 1 mass %, it is not preferred since a sufficient rust-preventive property cannot be attained. The lower limit of the content is more preferably 2 mass %, furthermore preferably 3 mass %. The upper limit is preferably 30 mass %, more preferably 15 mass %.

Further, the metal surface treatment composition of the present invention preferably comprises a water-borne resin. A water-borne resin used herein is one containing a water-soluble resin and a water-dispersible resin. The water-borne resin is not particularly limited, and examples thereof may include acrylic resins, polyolefinic resins, polyurethane resins, epoxy resins, olefin-acrylic acid copolymer resins, phenolic resins, polyester resins, alkyd resins, melamine resins, polycarbonate resins and polyacrylic acid, and another thermally crosslinking type and thermoplastic type resins.

These water-borne resins may be used alone or in combination of two or more species, or in the form of copolymers or block polymers thereof. When the water-borne resin is used, a leveling agent, a wetting agent and an antifoaming agent may be used in order to improve a film forming property and form a more uniform and smooth film.

When the metal surface treatment composition of the present invention comprises the water-borne resin, the content of the water-borne resin is preferably within a range of 5 mass % (lower limit) to 90 mass % (upper limit) relative to the total nonvolatile matter in the metal surface treatment composition. When the content exceeds 90 mass %, it is not preferred since the adding effect will saturate in this range and the addition becomes uneconomical. When it is less than 5 mass %, it is not preferred since the rust-preventive property may deteriorate. The lower limit is more preferably 10 mass %, furthermore preferably 20 mass %. The upper limit is more preferably 80 mass %, furthermore preferably 70 mass %.

Preferably, the metal surface treatment composition of the present invention further comprises water-dispersible silica in order to improve the rust-preventive property of a surface treatment film. The water-dispersible silica cannot attain an adequate rust-preventive property when it is used alone, but it can improve the rust-preventive property multiplicatively by being used in combination with the niobium oxide colloidal particles.

The water-dispersible silica is not particularly limited, and examples thereof may include spherical silica, chain silica and aluminum-modified silica, which have fewer impurities such as sodium and the like. The spherical silica is not particularly limited, and examples thereof may include colloidal silica such as “SNOWTEX N”, “SNOWTEX O”, “SNOWTEX OXS” and “SNOWTEX UP” (each made by Nissan Chemical Industries, Ltd.) and fumed silica such as “AEROSIL” (made by Nippon Aerosil Co., Ltd.). The chain silica is not particularly limited, and examples thereof may include silica sol such as “SNOWTEX PS-M” and “SNOWTEX PS-MO” (each made by Nissan Chemical Industries, Ltd.). Examples of the aluminum-modified silica may include commercially available silica gel such as “ADELITE AT-20A” (made by Asahi Denka Co., Ltd.)

When the metal surface treatment composition of the present invention comprises the water-dispersible silica, the content of SiO₂ in the metal surface treatment composition is preferably 80 mass % or less relative to the total nonvolatile matter in the metal surface treatment composition. When the content exceeds 80 mass %, there is a problem that a coat becomes brittle and a rust-preventive property deteriorates. The upper limit is more preferably 60 mass %, furthermore preferably 30 mass %.

Preferably, the metal surface treatment composition of the present invention further comprises at least one compound selected from the group consisting of vanadium compounds, zirconium compounds and titanium compounds in order to improve the rust-preventive property of a surface treatment film. It is possible to further improve the rust-preventive property by using the niobium oxide colloidal particles in combination with the at least one compound selected from the group consisting of vanadium compounds, zirconium compounds and titanium compounds. It is more preferred to use four, five or six components of the niobium oxide colloidal particles, the water-borne resin, the water-dispersible silica, and the at least one compound selected from the group consisting of vanadium compounds, zirconium compounds and titanium compounds in combination.

The vanadium compound, zirconium compound and titanium compound are not particularly limited as long as they are water-soluble or water-dispersible compounds, and specific examples thereof are as follows.

The vanadium compound is not particularly limited, and examples thereof may include vanadyl compounds, vanadium pentoxide, vanadates, burned polyvanadic acid, heteropoly vanadic acid and mixtures thereof. Specific examples thereof may include vanadium (II) compounds such as vanadium (II) oxide, and vanadium (II) hydroxide; vanadium (III) compounds such as vanadium (III) oxide (V₂O₃); vanadium (IV) compounds such as vanadium (IV) oxide (V₂O₄), and vanadyl halides (VOX₂); vanadium (V) compounds such as vanadium (V) oxide (V₂O₅); vanadates such as various orthovanadates, metavanadates or pyrovanadates, vanadyl halides (VOX₃); or mixtures thereof. Vanadates are not particularly limited, and examples thereof may include ammonium salt, alkaline metal salts, alkaline earth metal salts (for example, magnesium, calcium), metal salts of another typical elements (for example, aluminum, tin) and transition metal salts (for example, manganese, cobalt, iron, nickel). In particular, alkaline earth metal salts, zinc salt, manganese salt, and cobalt salt are preferred. These may be obtained by burning oxides of vanadium and oxides, hydroxides or carbonates of various metals together at a temperature of 600° C. or more.

The zirconium compound is not particularly limited, and examples thereof may include fluorozirconic acid (H₂ZrF₆); ammonium, lithium, sodium, or potassium salts of fluorozirconic acid; ammonium zirconate oxycarbonate ((NH₄)₂ZrO (CO₃)₂); zirconate compounds such as zirconium hydroxide, zirconium carbonate, zirconium borate, zirconium oxalate, zirconium sulfate, zirconium nitrate, zirconyl nitrate, and zirconium fluoride; organic zirconate compounds such as dibutylzirconium dilaurate, dibutylzirconium dioctate, zirconium naphthenate, zirconium octylate, and acetylacetone zirconium; or mixtures thereof.

The titanium compound is not particularly limited, and examples thereof may include fluorine-titanium compounds such as fluorotitanic acid, ammonium fluorotitanate, sodium fluorotitanate, potassium fluorotitanate, fluorotitanic acid, alkaline metal fluorotitanate, and titanium fluoride; organic titanium compounds such as titanium potassium oxalate, titanium isopropoxide, isopropyl titanate, titanium ethoxide, titanium 2-ethyl 1-hexanolate, tetraisopropyl titanate, tetran-butyl titanate, butyltitanate dimer, titanium lactate, and titanium triethanolaminate; or mixtures thereof.

When the metal surface treatment composition of the present invention comprises at least one compound selected from the group consisting of the vanadium compounds, the zirconium compounds and the titanium compounds, the content of the compounds is preferably within a range of 0.1 mass % (lower limit) to 30 mass % (upper limit) on the V, Zr or Ti basis relative to the total nonvolatile matter in the metal surface treatment composition. When the content exceeds 30 mass %, it is not preferred since the adding effect will saturate in this range and the addition becomes uneconomical. When it is less than 0.1 mass %, it is not preferred since the rust-preventive property may deteriorate. The lower limit is more preferably 0.5 mass %, furthermore preferably 1.0 mass %. The upper limit is more preferably 15 mass %, furthermore preferably7.5 mass %. Incidentally, since some kinds of compounds to be used may cause the gelation and thickening of the metal surface treatment composition and the solution stability may deteriorate, it is necessary to blend the compounds within a preferred range.

Preferably, the metal surface treatment composition of the present invention further contains a silane coupling agent. It is preferred in that by containing the silane coupling agent, the adhesion of a coat to a metal surface can be improved and the silane coupling agent has an action as a crosslinking agent of the water-borne resin and thereby the corrosion resistance can be improved. The silane coupling agent is not particularly limited, and examples thereof may include vinylmethoxysilane, vinyltrimethoxysilane, vinylethoxysilane, vinyltriethoxysilane, 3-aminopropyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, N-(1,3-dimethylbutylidene)-3-(triethoxysilyl)-1-propane amine, N,N′-bis[3-(trimethoxysilyl)propyl]ethylenediamine, (N-β-aminoethyl)-γ-aminopropylmethyldimethoxysilane, (N-β-aminoethyl)-γ-aminopropyltrimethoxysilane, γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane, γ-glycidoxypropylmethyldimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, γ-methacryloxypropyltrimethoxysilane, γ-methacryloxypropyltriethoxysilane, γ-mercaptopropyltrimethoxysilane, γ-mercaptopropyltriethoxysilane and N-[2-(vinylbenzylamino)ethyl]-3-aminopropyltrimethoxysilane.

Among them, examples of the particularly preferred silane coupling agent may include vinylmethoxysilane, vinylethoxysilane, 3-aminopropyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane and N-(1,3-dimethylbutylidene)-3-(triethoxysilyl)-1-propane amine, N,N′-bis[3-(trimethoxysilyl)propyl]ethylenediamine. The silane coupling agent may be used alone or in combination of two or more species.

When the metal surface treatment composition of the present invention comprises the silane coupling agent, the content of the silane coupling agent in the metal surface treatment composition is preferably within a range of 0.5 mass % (lower limit) to 30 mass % (upper limit) relative to the total nonvolatile matter in the metal surface treatment composition. When the content of the silane coupling agent is less than 0.5 mass %, it is not preferred since the effect of improving corrosion resistance and adhesion to a chromium-free rust-preventive coating agent may be insufficient, and when it exceeds 30 mass %, it is not preferred since the adding effect will saturate in this range and the addition becomes uneconomical, and in addition the gelation and thickening of the composition may arise and the solution stability may deteriorate. The lower limit is more preferably 1 mass % and the upper limit is more preferably 20 mass %.

The metal surface treatment composition of the present invention preferably contains a phosphate compound. The phosphate compound contained in the metal surface treatment composition of the present invention has a function of further improving the rust-preventive property of a surface treatment film by eluting metal, being a material to be treated, and forming a metal salt of phosphate on the surface of the material to be treated.

The phosphate compound is not particularly limited as long as it is a compound capable of forming phosphate ions in water, and examples thereof may include phosphorous acid, hypophosphorous acid, organic phosphoric acids, organic phosphorous acids, phosphoric acid; phosphate salts such as Na₃PO₄, Na₂HPO₄ and NaH₂PO₄; and polyphosphoric acid such as polyphosphoric acid, metaphosphoric acid, pyrophosphoric acid and ultraphosphoric acid, and salts thereof.

When the metal surface treatment composition of the present invention comprises the phosphate compound, the content of the phosphate compound in the metal surface treatment composition is preferably within a range of 0.1 mass % (lower limit) to 20 mass % (upperlimit) relative to the total solid matter in the metal surface treatment composition. When the content is less than 0.1 mass %, it is not preferred since the effect of improving the corrosion resistance may be insufficient, and when it exceeds 20 mass %, it is not preferred since this may cause excessive etching on a galvanized steel plate or the gelation of the composition. The lower limit is more preferably 0.5 mass % and the upper limit is more preferably 10 mass %.

The metal surface treatment composition of the present invention preferably has pH within a range of 6 (lower limit) to 11 (upper limit). When the pH is less than 6, the stability in mixing the niobium oxide sol may deteriorate and the solution stability of the whole compositions may deteriorate, and in addition this pH may cause excessive etching on a galvanized steel plate to lead to a defective appearance. When it exceeds 11, it is not preferred since this pH may cause excessive etching on a galvanized steel plate to lead to a defective appearance. The lower limit is more preferably 7 and the upper limit is more preferably 10. The pH of the metal surface treatment composition is preferably adjusted within the range by adding a basic compound. Particularly, it is more preferred to use volatile compounds such as ammonia and amines as the basic compound.

The metal surface treatment composition of the present invention preferably contains nonvolatile matter within a range of 3 mass % (lower limit) to 50 mass % (upper limit) on-the mass of the nonvolatile matter basis. When the concentration of the nonvolatile matter is less than 3 mass %, it is not preferred since it may be impossible to attain an sufficient film thickness for maintaining the rust-preventive property in applying the metal surface treatment composition. When it exceeds 50 mass %, it is not preferred since this may cause the gelation of the composition. The lower limit is more preferably 10 mass % and the upper limit is more preferably 30 mass %.

The niobium oxide colloidal particles highly stabilized by the citric acid or salts thereof to be used in the present invention also has the excellent stability in mixing with such electrolyte components as described above. Therefore, the metal surface treatment composition of the present invention, which comprises the respective components described above, is superior in the stability, so that it can perform the surface treatment of a galvanized steel plate with stability.

A method of producing the metal surface treatment composition of the present invention is not particularly limited, and it can be obtained, for example, by charging the niobium oxide colloidal particles, the water-borne resin, the water-dispersible silica, at least one compound selected from the group consisting of vanadium compounds, zirconium compounds and titanium compounds, the silane coupling agent and the phosphate compound to a container in this order and by stirring the resulting mixture so as to become uniform.

The metal surface treatment method of the present invention is a method in which a galvanized steel plate is treated with the metal surface treatment composition. A galvanized steel plate, which can be treated in the metal surface treatment method of the present invention, is not particularly limited, and examples thereof may include steel plates, which are plated with zinc or a zinc-based alloy through electroplating, hot dipping and vacuum evaporation coating, such as a galvanized steel plate, a steel plate plated with a zinc-nickel alloy, a steel plate plated with a zinc-iron alloy, a steel plate plated with a zinc-chromium alloy, a steel plate plated with a zinc-aluminum alloy, a steel plate plated with a zinc-titanium alloy, a steel plate plated with a zinc-magnesium alloy and a steel plate plated with a zinc-manganese alloy.

In the metal surface treatment method, the galvanized steel plate degreased as required is treated with the metal surface treatment composition. The treating method with the metal surface treatment composition is not particularly limited, and examples thereof may include roller coating, shower coating, air-spray coating, airless-spray coating, curtain flow coating, brush coating and immersion coating, which are commonly used.

Preferably, the metal surface treatment composition of the present invention is applied in an application rate of 0.1 g/m² (lower limit) to 10.0 g/m² (upper limit) as amass of the nonvolatile matter in a coat. When this application rate is less than 0.1 g/m², there may be cases where the ability to be processed deteriorates or the rust-preventive property is not adequately attained due to insufficient thickness. When it exceeds 10.0 g/m², there may be cases where it is economically disadvantageous since there is not an increase in the effect of increasing a film thickness or winding becomes difficult due to the increased thickness. The lower limit is more preferably 0.2 g/m², and furthermore preferably 0.3 g/m². The upper limit is more preferably 5.0 g/m², and furthermore preferably 3.0 g/m².

It is preferred to dry the coat by heating after treating with the metal surface treatment composition. A temperature, at which the drying is conducted, is preferably within a range of 50° C. (lower limit) to 250° C. (upper limit). When it is less than 50° C., drying efficiency may become worse due to a low evaporation rate of water. When it exceeds 250° C., formed components in a coat may be decomposed due to elevated temperatures. More preferably, the lower limit is 60° C. and the upper limit is 150° C. Drying time is preferably in a rage of 1 second (lower limit) to 300 seconds (upper limit), and more preferably in a rage of 3 seconds (lower limit) to 60 seconds (upper limit).

The present invention also provides a galvanized steel plate obtained by the metal surface treatment method. Since the galvanized steel plate of the present invention is one on which a good surface treatment coat is formed, it has an excellent rust-preventive property and does not form white color rust.

The metal surface treatment composition of the present invention is one which comprises the niobium oxide colloidal particles having the excellent stability and provides the galvanized steel plate with the good rust-preventive property and adhesion equal to a chromate-treatment agent without requiring a burden of waste water treatment. By using the metal surface treatment composition, it is possible to provide the method of metal surface treatment, which can apply a good metal surface treatment to a galvanized steel plate. Further, by using the method of metal surface treatment of the present invention, it is possible to provide a galvanized steel plate which has the excellent rust-preventive property and adhesion.

Since the metal surface treatment composition of the present invention includes the niobium oxide colloidal particles highly stabilized with citric acid or salts thereof, it has the excellent solution stability and provides the good rust-preventive property and adhesion for a film to be obtained. Further, since the metal surface treatment composition of the present invention does not contain components such as chromium and manganese as an essential component, it does not require an excessive burden of waste water treatment.

EXAMPLES

Hereinafter, the present invention will be described in detail by way of examples, but the present invention is not limited to these examples. In addition, “%” refers to “mass %” in the examples, unless otherwise specified.

Preparation of Metal Surface Treatment Compositions

Examples 1 to 16, and Comparative Examples 1 to 3

Charged To a container were water-dispersible silica, a vanadium compound, a zirconium compound, a titanium compound, niobium oxide colloidal particles, a water-borne resin, a silane coupling agent and a phosphate compound in this order under being stirred. After stirring for 30 minutes, deionized water was added to this mixture to prepare metal surface treatment compositions having the composition shown in Table 1. Concentrations of the nonvolatile matter and pHs of the obtained metal surface treatment compositions are shown in Table 2.

Comparative Example 4

A metal surface treatment composition having the composition shown in Table 1 was prepared by following the same procedure as in Example 15 except for changing the niobium oxide colloidal particles to K₂NbF₇ (made by Morita Chemical Industries Co., Ltd.), which is a soluble niobium compound. A concentration of the nonvolatile matter and pH of the obtained metal surface treatment composition is shown in Table 2.

The niobium oxide colloidal particles, the water-borne resins, the water-dispersible silica, the vanadium compounds, the zirconium compounds, the titanium compounds, the silane coupling agents and the phosphate compounds used in Table 1 were as follows.

[Niobium Oxide Colloidal Particle]

A: niobium oxide sol (Nb₂O₅: 10%, average particle diameter: 5 nm, pH 4, citric acid/niobium (mole ratio)=0, made by Taki Chemical Co., Ltd.)

B: niobium oxide sol SAM-02 (Nb₂O₅: 10%, average particle diameter: 5 nm, pH 3.8, citric acid/niobium (mole ratio)=0.05, made by Taki Chemical Co., Ltd.)

C: niobium oxide sol SAM-04 (Nb₂O₅: 5%, average particle diameter: 10 nm, pH 9, citric acid/niobium (mole ratio)=0.16, made by Taki Chemical Co., Ltd.)

[Water-Borne Resin]

A: PC 2200 (ethylene-acrylic acid copolymer resin, concentration of nonvolatile matter: 30%, made by SHOEI CHEMICAL CO., LTD.)

B: SUPERFLEX 420 (polyurethane resin, concentration of nonvolatile matter: 32%, made by DAI-ICHI KOGYO SEIYAKU CO., LTD.)

C: JURYMERAC-10L (polyacrylic acid, concentration of nonvolatile matter: 40%, made by NIHON JUNYAKU CO., LTD.)

[Water-Dispersible Silica]

A: SNOWTEX O (SiO₂: 20%, made by Nissan Chemical Industries, Ltd.)

B: ADELITE AT-20A (SiO₂: 20%, made by Asahi Denka Co., Ltd.)

C; SNOWTEX N (SiO₂: 20%, made by Nissan Chemical Industries, Ltd.)

[Vanadium Compound]

A: ammonium metavanadate (V: 43.6%, reagent)

B: vanadium pentoxide (V: 56.0%, reagent)

C: sodium metavanadate (V: 41.8%, reagent)

[Zirconium Compound]

A: Zircosol AC-7 (zirconium ammonium carbonate, Zr: 74.0% (on the solid matter basis), made by DAIICHI KIGENSO KAGAKU KOGYO CO., LTD.)

B: (acetylacetonato) zirconium (IV) (Zr: 18.7%, reagent)

[Titanium Compound]

A: Orgatics TC-400 (titanium triethanolaminate, Ti: 10.4% (on the solid matter basis), made by Matsumo to Chemical Industry Co., Ltd.)

[Silane Coupling Agent]

A: Sila-Ace S-510 (γ-glycidoxypropyltrimethoxysilane, concentration of nonvolatile matter: 100%, made by CHISSO CORPORATION)

B: Sila-Ace S-210 (vinyltrimethoxysilane, concentration of nonvolatile matter: 100%, made by CHISSO CORPORATION)

[Phosphate Compound]

A: diammonium hydrogen phosphate (concentration of nonvolatile matter: 100%, reagent)

	TABLE 1
	Metal surface treatment composition (mass % relative to the total nonvolatile matter)
			Water-
	Niobium oxide colloidal particles	Water-borne	dispersible	Vanadium	Zirconium
	Mole ratio of		resin	silica	compound	compound
		Kinds	Mass %	citric acid	pH	Kinds	Mass %	Kinds	Mass %	Kinds	Mass %	Kinds	Mass %
Example	1	C	100	0.16	9.0	—	—	—	—	—	—	—	—
	2	C	30	0.16	9.0	A	70	—	—	—	—	—	—
	3	B	30	0.05	3.8	A	70	—	—	—	—	—	—
	4	C	30	0.16	9.0	A	40	C	30	—	—	—	—
	5	C	1	0.16	9.0	A	70	B	29	—	—	—	—
	6	C	10	0.16	9.0	A	30	A	60	C	10 (V: 4.2)	—	—
	7	C	10	0.16	9.0	A	30	C	59	—	—	A	1.0 (Zr: 0.7)
	8	C	10	0.16	9.0	B	30	C	55	—	—	A	5.0 (Zr: 3.7)
	9	C	1	0.16	9.0	A	90	C	8.8	B	0.2 (V: 0.1)	—	—
	10	C	10	0.16	9.0	C	10	C	42	—	—	A	38 (Zr: 28.1)
	11	C	20	0.16	9.0	A	55	C	5	—	—	B	20 (Zr: 3.7)
	12	C	10	0.16	9.0	A	5	A	80	A	5.0 (V: 2.2)	—	—
	13	C	5	0.16	9.0	A	65	A	20	C	10 (V: 4.2)	—	—
	14	C	7	0.16	9.0	A	65	A	24	A	2.0 (V: 0.9)	—	—
	15	C	7	0.16	9.0	A	64	A	24	A	2.0 (V: 0.9)	—	—
	16	C	7	0.16	9.0	A	63	A	24	A	2.0 (V: 0.9)	—	—
Comparative	1	—	—	—	—	A	70	A	28	A	2.0 (V: 0.9)	—	—
Example	2	—	—	—	—	A	70	A	24	A	2.0 (V: 0.9)	—	—
	3	A	10	0	4.0	A	30	A	50	A	10 (V: 4.4)	—	—
	4	K2NbF7:16 (Nb2O5: 7)	C	64	A	15	A	2.0 (V: 0.9)	—	—
	Metal surface treatment composition (mass % relative
	to the total nonvolatile matter)
	Titanium	Silane	Phosphate
	compound	coupling agent	compound
			Kinds	Mass %	Kinds	Mass %	Kinds	Mass %
	Example	1	—	—	—	—	—	—
		2	—	—	—	—	—	—
		3	—	—	—	—	—	—
		4	—	—	—	—	—	—
		5	—	—	—	—	—	—
		6	—	—	—	—	—	—
		7	—	—	—	—	—	—
		8	—	—	—	—	—	—
		9	—	—	—	—	—	—
		10	—	—	—	—	—	—
		11	—	—	—	—	—	—
		12	—	—	—	—	—	—
		13	—	—	—	—	—	—
		14	A	2.0 (Ti: 0.2)	—	—	—	—
		15	A	2.0 (Ti: 0.2)	A	1.0	—	—
		16	A	2.0 (Ti: 0.2)	B	1.0	A	1.0
	Comparative	1	—	—	—	—	—	—
	Example	2	A	2.0 (Ti: 0.2)	A	1.0	A	1.0
		3	—	—	—	—	—	—
		4	A	2.0 (Ti: 0.2)	A	1.0	—	—

Preparation of Test Panels

Commercially available galvanized steel plates (manufactured by Nippon Testpanel Co., Ltd., 70 mm×150 mm×0.4 mm) were degreased by spraying at 60° C. for 2 minutes using SURF CLEANER 53S (made by NIPPON PAINT Co., Ltd.), being a commercially available alkaline degreasing agent, and rinsed with water and dried. After drying the steel plates, the metal surface treatment compositions prepared in Examples 1 to 16 and Comparative Examples 1 to 4 were applied to the steel plates with a barcoater in such a way that an application rate after drying was 0.2 to 1.0 g/m² of surface area and then dried at a metal surface temperature of 80° C. to obtain test panels. The resulting test panels were evaluated according to the following methods. The results of measurements are shown in Table 2. The application rate was given by analyzing metal elements in the composition using “XRF-1700” (X-ray fluorescence spectrometer manufactured by Shimadzu Corp.) to yield the contents by mass % of metal elements relative to total nonvolatile matter and converting the content.

(Evaluation Methods)

<Corrosion Resistance>

A flat portion of each test panel and an end face and a rear face of a formed portion, which was extruded by 8 mm by an Erichsen tester, in each test panel were sealed with a tape and 5% salt water was sprayed to the coated surface of the test panel at 35° C. After a lapse of 72 hours since salt water spray, a rate of the surface area where white color rust was generated was evaluated according to the following criteria.

• ⊚: no white color rust occurred
• ◯: less than 10% ratio of the surface area where white color rust occurred
• ◯Δ: not less than 10% and less than 30% of that ratio
• Δ: not less than 30% and less than 50% of that ratio
• ×: not less than 50% of that ratio
  <Film Appearance>

The appearance of the test panels was visually evaluated according to the following criteria.

	TABLE 2
	Concentration of		Corrosion resistance
	nonvolatile		(SST 72 hours)
	matter in	pH of			Portion formed
	treatment	treatment	Application	Flat	by Erichsen	Film	Solution
	composition (%)	composition	rate (g/m2)	portion	tester	Appearance	stability
Examples	1	5	9.0	1.0	◯Δ	◯Δ	⊚	⊚
	2	10	8.7	0.8	◯	◯	⊚	⊚
	3	5	6.0	0.8	◯	◯	◯	◯
	4	10	8.6	0.8	⊚	◯	⊚	⊚
	5	10	9.0	0.8	◯	◯Δ	⊚	⊚
	6	10	8.4	0.4	⊚	⊚	⊚	⊚
	7	10	8.6	0.6	⊚	◯	⊚	⊚
	8	5	8.6	0.4	⊚	⊚	⊚	⊚
	9	10	8.7	0.6	◯	◯	⊚	⊚
	10	5	8.4	0.6	⊚	⊚	⊚	◯
	11	5	8.4	0.5	⊚	⊚	⊚	⊚
	12	5	7.8	0.6	⊚	◯	⊚	⊚
	13	10	8.4	0.4	⊚	⊚	⊚	◯
	14	20	8.4	0.4	⊚	⊚	⊚	⊚
	15	20	8.4	0.3	⊚	⊚	⊚	⊚
	16	20	8.4	0.2	⊚	⊚	⊚	⊚
Comparative	1	15	8.5	0.8	Δ	X	⊚	⊚
Examples	2	15	8.5	0.4	Δ	Δ	⊚	⊚
	3	5	4.0	0.4	⊚	⊚	Δ	X
	4	7	3.0	0.4	Δ	Δ	X	Δ

As shown in Table2, the metal surface treatment compositions obtained in Examples 1 to 16 were superior in the solution stability and the films obtained by applying the metal surface treatment compositions had the high corrosion resistance and the good appearances. On the other hand, since the metal surface treatment compositions obtained in Comparative Examples 1 and 2 could not attain chemical conversion coats which had excellent rust-preventive property, they could not obtain good galvanized steel plates. In addition, the metal surface treatment composition obtained in Comparative Example 3 was not good in the solution stability and the appearance of the obtained film was inferior to that of Examples. Further, the metal surface treatment composition of Comparative Example 4, not containing the niobium oxide colloidal particles, exhibited thickening of solution by secular changes and the appearance and the corrosion resistance of the obtained film were not satisfactory.

Claims

1. A metal surface treatment composition comprising niobium oxide colloidal particles,

wherein the niobium oxide colloidal particles are derived from a niobium oxide sol which is stabilized by containing citric acid or salts thereof in an amount of 0.02 to 1.0 by a mole ratio relative to Nb.

2. The metal surface treatment composition according to claim 1,

wherein the niobium oxide colloidal particle has an average particle diameter of 100 nm or less.

3. The metal surface treatment composition according to claim 1 or 2,

wherein the niobium oxide colloidal particle has a content of 1 mass % or more relative to the total nonvolatile matter in the metal surface treatment composition when Nb contained in the niobium oxide colloidal particle is converted to equivalent Nb2O5.

4. The metal surface treatment composition according to claim 1 or 2, comprising

a water-borne resin in an amount of 5 to 90 mass % relative to the total nonvolatile matter in the metal surface treatment composition.

5. The metal surface treatment composition according to claim 4,

wherein the water-borne resin is at least one kind selected from the group consisting of acrylic resin, polyolefinic resin, polyurethane resin, epoxy resin, olefin-acrylic acid copolymer resin, phenolic resin, polyester resin, alkyd resin, melamine resin, polycarbonate resin, polyacrylic acid and copolymers or block polymers thereof.

6. The metal surface treatment composition according to claim 1 or 2, comprising

water-dispersible silica in an amount of 80 mass % or less relative to the total nonvolatile matter in the metal surface treatment composition.

7. The metal surface treatment composition according to claim 1 or 2, comprising

at least one compound selected from the group consisting of vanadium compounds, zirconium compounds and titanium compounds in an amount of 0.1 to 30 mass % on the V, Zr or Ti basis relative to the total nonvolatile matter in the metal surface treatment composition.

8. The metal surface treatment composition according to claim 1 or 2, comprising

a silane coupling agent in an amount of 0.5 to 30 mass % relative to the total nonvolatile matter in the metal surface treatment composition.

9. The metal surface treatment composition according to claim 1 or 2, comprising

a phosphate compound in an amount of 0.1 to 20 mass % relative to the total nonvolatile matter in the metal surface treatment composition.

10. The metal surface treatment composition according to claim 1 or 2,

wherein pH is 6 to 11.

11. The metal surface treatment composition according to claim 1 or 2,

wherein the concentration of the nonvolatile matter is 3 to 50 mass % on the mass of the nonvolatile matter basis.

12. A metal surface treatment method

applying surface treatment to a galvanized steel plate with the metal surface treatment composition according to claim 1 or 2, thereby forming a coat thereof.

13. A coated galvanized steel plate obtained by the metal surface treatment method according to claim 12.