Corrosion-resistant coated copper and method for making the same

Abstract

A corrosion-resistant coated base metal coated with a corrosion resistant alloy. The corrosion resistant alloy includes tin and zinc. The corrosion resistant coated base metal includes a heat created intermetallic layer primarily including copper and zinc.

Description

[0001] This patent application is a continuation of Ser. No. 10 / 849,717 filed May 20, 2004, which in turn is a continuation of Ser. No. 10 / 254,824 filed Sep. 24, 2002, which in turn is a continuation-in-part of Ser. No. 10 / 144,128 filed May 10, 2002, now abandoned, which in turn is a continuation of Ser. No. 09 / 634,828 filed Aug. 9, 2000, now abandoned, which in turn is a continuation-in-part of Ser. No. 08 / 929,623 filed Sep. 15, 1997, now abandoned, which in turn is a continuation-in-part of Ser. No. 08 / 604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No. 08 / 551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08 / 402,925 filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser. No. 08 / 165,085 filed Dec. 10, 1993, now U.S. Pat. No. 5,397,652, which in turn is a continuation-in-part of Ser. No. 08 / 000,101 filed Jan. 4, 1993, now abandoned, which in turn...

AI Technical Summary

Benefits of technology

[0039] In accordance with another and / or alternative aspect of the invention, a metal alloy is a tin alloy, as defined above, that primarily includes tin, and zinc content is equal to or less than the minimum eutectic weight percentage of zinc in the tin alloy. As such, the tin alloy is a metal alloy that includes at least a majority of tin and less than 9-10 weight percent zinc. The corrosion resistant tin alloy forms a corrosion resistant coating that protects the surface of the base metal from oxidation. The corrosion resistant tin alloy provides protection to the base metal in a variety of environments such as rural, industrial, and / or marine environments. The corrosion resistant tin alloy also performs well in low temperatures; has a relatively low coefficient of thermal expansion; has a pleasing color; resists degradation by solar energy; can be molded, cast, formed, drawn, soldered, painted and / or colored; and / or can be installed in a variety of weather conditions. Because of the relative inertness of the tin oxide in many environments, the corrosion resistant tin alloy is considered to be environmentally safe and friendly and considered a safe material to be used in the human environment. The corrosion resistant tin alloy is also a cost-effective material for use in structures erected in corrosive environments, such as in the tropics and other areas where buildings are exposed to strong winds, corrosive fumes, and / or marine conditions. In one embodiment of the invention, the tin content in the tin alloy makes up more than 50 weight percent of the tin alloy. In one aspect of this embodiment, the tin content in the tin alloy is at least about 75 weight percent of the tin alloy. In another and / or alternative aspect of this embodiment, the tin content in the tin alloy is at least about 80 weight percent of the tin alloy. In yet another and / or alternative aspect of this embodiment, the tin content in the tin alloy is at least about 85 weight percent of the tin alloy. In still yet another and / or alternative aspect of this embodiment, the tin content in the tin alloy is at least about 90 weight percent of the tin alloy. In a further and / or alternative aspect of this embodiment, the tin content in the tin alloy is at least about 95 weight percent of the tin alloy. In yet a further and / or alternative aspect of this embodiment, the tin content in the tin alloy is at least about 98 weight percent of the tin alloy. In still a further and / or alternative aspect of this embodiment, the tin content in the tin alloy is at least about 99 weight percent of the tin alloy.

[0118] Still yet a further and / or alternative object of the present invention is the provision of producing a highly corrosion-resistant coated base material that is economical to make.

Problems solved by technology

Because of the environmentally-un-friendly nature of lead, the gasoline tanks of vehicles must be removed prior to the recycling of the vehicle.

Although terne coated metals have excellent corrosion-resistant properties and have been used in various applications, terne coated materials have been questioned due to environmental concerns based on the high lead content of the alloy.

Not only do these the terne coated articles take up space in the landfills, but there is a concern with the lead leaching from the terne coating into the landfill site and potentially contaminating the surrounding area and underground water reservoirs.

In many remote locations throughout the world, piped water or well water is not readily available.

Roof systems have been made of other metals, but to much less extent due to higher cost and natural corrosion resistance.

However, in some limited applications, these metals have been coated with terne to extend the life of these metals.

However, as with lead piping, there is a concern that the lead in the terne coated roofing materials results in lead dissolving in the collected water.

These exposed surfaces typically corroded at a faster rate than the unexposed surfaces.

The corroded regions about the coated areas, in some instances, compromised the adherence of the coated area, thereby resulting, in some instances, to flaking of the coated regions.

These corroded regions compromised, in some instances, rapidly compromised the structural integrity, safety and / or performance of the coated base metal.

Another disadvantage of using a terne alloy coating is the softness of the terne layer.

The softness of the terne coating is susceptible to damage from the abrasive nature of forming machines and to environments that subject the terne coating to frequent contact with other materials.

Terne alloys have a further disadvantage in that the newly applied terne is very shiny and highly reflective.

As a result, in some building applications, the highly reflective coating cannot immediately be used.

The terne coating eventually loses its highly reflective properties as the components of the terne coating are reduced (weathered); however, the desired amount of reduction commonly takes about 1.5 to two years when the terne coating is exposed to the atmosphere.

The storage of the terne coated base metal significantly prolongs the weathering of the terne coated materials.

Metallic coatings such as tin or zinc have been tested as substitutes for terne coatings with limited success.

The very thin thicknesses of the tin coating typically results in a tin coating having a network of small pinholes, thereby making the coated material generally unacceptable for use in corrosive environments, such as on building materials, marine materials, and automotive products.

Such tin plated base metals can include a flash or intermediate metal layer (plated layer) to reduce the pinhole problems inherent with the tin plating process; however, the corrosion effectiveness of the plated tin layer, in some applications, is less than terne coated materials.

The tin plated layer is also susceptible to flaking or being scrapped off when the tin plated base metal is drawn through a die and / or formed into various components.

The flaking of the tin coating can also cause premature clogging of filter systems and liquid lines, such as in gasoline lines and filters, when the tin plated based metals are formed into gasoline tanks.

The pinholes problem, flaking and / or scraping problem that is associated with plated tin coatings is very problematic since tin is not electroprotective under oxidizing conditions.

Consequently, discontinuities in the plated tin coating can result in the corrosion of the exposed base metal.

Although zinc coatings bond to many types of metals, the bond is typically not very strong thereby resulting in the zinc coating flaking off the base metal over time and / or when being formed.

The flaking of zinc, like the flaking of tin coatings, can cause premature clogging of filter systems and liquid lines when zinc coated base metal is formed into gasoline tanks or used in other liquid systems.

The flaking of the zinc coating can also result in an undesired and / or disfigured product over a short period of time.

Zinc also does not form a uniform and / or thick coating when coating on various types of base metals.

Zinc is also a very rigid and brittle metal, and tends to crack and / or flake off when the zinc coating is formed and / or drawn through a die.

This white powdery substance is undesirable for many building applications and in various other environments and applications.

Consequently, the use of a tin coating or a zinc coating as a substitute for terne coatings has not been highly reliable, commercially acceptable or a cost-effective substitute for traditional terne coatings.

The Japanese patent application discloses that after plating, pin holes exist in the coating and subject the coating to corrosion.

The '501 patent discloses that the molten tin and zinc alloy is very susceptible to oxidation resulting in viscous oxides forming on the surface of the molten tin and zinc alloy.

These viscous oxides cause severe problems with the coating process.

While the steel article is immersed in the molten alloy, a large amount of dross forms on the surface of the molten alloy.

The dross results in non-uniformity of the coating and the formation of pin holes as the steel article is removed from the molten metal.

The beneficial effect of the zinc is null; however, when more than 30% zinc is used, the coating will rapidly corrode under adverse environments.

The use of copper base metals for architectural materials and other applications present unique challenges.

Generally, the copper alloys reduce the formability of the architectural materials.

This color change is unacceptable in a variety of applications.

Uncoated copper can also be used to collect water; however, the oxidized copper tends to mix with the water and adversely affects the taste and color of the water.

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