CA1125590A - Composite coated metal sheet - Google Patents
Composite coated metal sheetInfo
- Publication number
- CA1125590A CA1125590A CA342,573A CA342573A CA1125590A CA 1125590 A CA1125590 A CA 1125590A CA 342573 A CA342573 A CA 342573A CA 1125590 A CA1125590 A CA 1125590A
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- CA
- Canada
- Prior art keywords
- metal sheet
- composition
- coated
- coated metal
- coating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Paints Or Removers (AREA)
- Laminated Bodies (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A composite coated metal sheet suitable for outdoor building materials and having excellent weatherability, corrosion resistance and formability is provided by coating a metal sheet with a composite material essentially consisting of polyvinylchloride resin and micaceous aluminum powder, and in certain cases a metal powder and an alloy powder of zinc, tin and lead. The composite coated metal sheet may be overlaid with an acrylic-type resin film. Process of preparing the composite coated metal sheet is also disclosed.
A composite coated metal sheet suitable for outdoor building materials and having excellent weatherability, corrosion resistance and formability is provided by coating a metal sheet with a composite material essentially consisting of polyvinylchloride resin and micaceous aluminum powder, and in certain cases a metal powder and an alloy powder of zinc, tin and lead. The composite coated metal sheet may be overlaid with an acrylic-type resin film. Process of preparing the composite coated metal sheet is also disclosed.
Description
1~2~5 ~) The prese~lt invention rela-tes to a composite coated metal sheet which is suitable for outdoor building materials.
Conventional coated metal sheets for outdoor buil-ding materials are as follows:
1. Precoated Galvanized Sheets:
This product is a galvanized sheet coated with paint which is of the ~hermosetting acrylic-type, polyester type, silicon-type or fluorocarbon-type resin. The coating is 10 to 40 ~m in thickness.
Conventional coated metal sheets for outdoor buil-ding materials are as follows:
1. Precoated Galvanized Sheets:
This product is a galvanized sheet coated with paint which is of the ~hermosetting acrylic-type, polyester type, silicon-type or fluorocarbon-type resin. The coating is 10 to 40 ~m in thickness.
2. Polyvinylchloride-Metal Laminated Sheets This product is a galvanized sheet covered with semi-rigid or flexible polyvinylchloride resin film of 100 to 300 ~m thickness.
3. Polyacrylate-Metal Laminated Sheets This product is galvanized sheet covered with acrylic-type resin film of 50 to 100 ~m thlckness.
4. Polyacrylate-Polyvinylchloride-Metal Laminated Sheets This product is a polyvinylchloride-metal laminated sheet which is overlaid with acrylic-type resin film of 50 to 100 ~m thickness.
However, the above-mentioned coated metal sheets are not always adequate from the standpoint of economy and durability for outdoor building materials.
On the other hand, zinc rich paint or aluminum rich paint consisting of zinc powder or aluminum powder and organic polymer e.g. epoxy resin is used for protection of metal building materials. But such paint films are subject to cracking in industrial processes such as bending or roll forming because of low flexibility. Therefore these paints cannot be used for precoated material.
l~Z~5~) Accorclinyly, it is one of the objects of the present invention to produce a metal sheet coated with a composition containing polyvinylchloride resin, a metal powder, plastici-zer and stabilizer, said product having excellent weather-ability, corrosion resistance and formability.
It is another object of the present invention to produce the said product overlaid with an acrylic-type resin film, this product having superior weatherability, corrosion resistance and formability.
rrhe present invention thus provides a coated metal sheet which has excellent outdoor durability and formability and is economical.
More specifically, the present invention provides a metal sheet covered with a composite material comprising polyvinylchloride resin and micaceous aluminum powder, and in certain cases a metal powder such as zinc, tin and lead or alloy powders of these metals.
This composite coated metal sheet is produced by the following method. The metal sheet is precoated with adhesive, baked by heat treatment, coated with a composite material, in paste form5 containing polyvinylchloride resin, metal powder, plasticizer and stabilizer or by laminating the composite material as a film, and ~:hen baking, i.e. heat treatment. This product has excellent weatherability, corrosion resistance and formability.
Furthermore, in certain cases, this composite coated sheet may be overlaid with an acrylic-type resin film. This product has superior weatherability and corrosion resistance.
The present invention will be described below in more detail.
1~2~
We shall begin with the c:omposite coating.
The composite coating composition comprises poly-vinylchloride resin, micaceous aluminum powder, plasticizer, stabilizer, and in certain cases a metal powder such as zinc, tin and lead ancl alloys of these metals. The coating compo-sition may include agents such as piyment and filler etc. for the polyvinylchloride resin. Polyvinylchloride resin, which is one of the main components of the present invention, may include that polymerized by suspension polymerization, emul-sion polymerization and solution polymerization, and mayinclude homopolymers and copolymers.
Micaceous aluminum powder, which is the other one of the main components according to the present invention, may include a powder of under 10 ,um thickness, which powder is produced by ordinary industrial methods. A thickness of more than lO ~m is undesirable because it impairs the appearance of the coated surface. The particle diameter of aluminum powder is not restricted but a smaller size is preferred. Powders other than aluminum may be included for the purpose of further improving corrosion resistance, e.g.
the metal powders such as zinc, tin, lead and alloys of these metals. In these powders, a diameter of more than 70 ,um is undesirable because it impairs the appearance of the coating surface.
Plasticizers and stabilizers, which are components of the present invention, may include those conventionally used for polyvinylchloride resins.
An example of formula for the composite materials is as follows:
Polyvinylchloride: 100 parts micaceous aluminum powder: 5 - 70 1~255~i) metal powder other than aluminum powder 0 - 145 plasticizer: as needed stabilizer: as needed However, the total amount of micaceous aluminum powder a~ powder other than aluminum powder must not be over lS0 parts.
An amount of micaceous aluminum powder of less than
However, the above-mentioned coated metal sheets are not always adequate from the standpoint of economy and durability for outdoor building materials.
On the other hand, zinc rich paint or aluminum rich paint consisting of zinc powder or aluminum powder and organic polymer e.g. epoxy resin is used for protection of metal building materials. But such paint films are subject to cracking in industrial processes such as bending or roll forming because of low flexibility. Therefore these paints cannot be used for precoated material.
l~Z~5~) Accorclinyly, it is one of the objects of the present invention to produce a metal sheet coated with a composition containing polyvinylchloride resin, a metal powder, plastici-zer and stabilizer, said product having excellent weather-ability, corrosion resistance and formability.
It is another object of the present invention to produce the said product overlaid with an acrylic-type resin film, this product having superior weatherability, corrosion resistance and formability.
rrhe present invention thus provides a coated metal sheet which has excellent outdoor durability and formability and is economical.
More specifically, the present invention provides a metal sheet covered with a composite material comprising polyvinylchloride resin and micaceous aluminum powder, and in certain cases a metal powder such as zinc, tin and lead or alloy powders of these metals.
This composite coated metal sheet is produced by the following method. The metal sheet is precoated with adhesive, baked by heat treatment, coated with a composite material, in paste form5 containing polyvinylchloride resin, metal powder, plasticizer and stabilizer or by laminating the composite material as a film, and ~:hen baking, i.e. heat treatment. This product has excellent weatherability, corrosion resistance and formability.
Furthermore, in certain cases, this composite coated sheet may be overlaid with an acrylic-type resin film. This product has superior weatherability and corrosion resistance.
The present invention will be described below in more detail.
1~2~
We shall begin with the c:omposite coating.
The composite coating composition comprises poly-vinylchloride resin, micaceous aluminum powder, plasticizer, stabilizer, and in certain cases a metal powder such as zinc, tin and lead ancl alloys of these metals. The coating compo-sition may include agents such as piyment and filler etc. for the polyvinylchloride resin. Polyvinylchloride resin, which is one of the main components of the present invention, may include that polymerized by suspension polymerization, emul-sion polymerization and solution polymerization, and mayinclude homopolymers and copolymers.
Micaceous aluminum powder, which is the other one of the main components according to the present invention, may include a powder of under 10 ,um thickness, which powder is produced by ordinary industrial methods. A thickness of more than lO ~m is undesirable because it impairs the appearance of the coated surface. The particle diameter of aluminum powder is not restricted but a smaller size is preferred. Powders other than aluminum may be included for the purpose of further improving corrosion resistance, e.g.
the metal powders such as zinc, tin, lead and alloys of these metals. In these powders, a diameter of more than 70 ,um is undesirable because it impairs the appearance of the coating surface.
Plasticizers and stabilizers, which are components of the present invention, may include those conventionally used for polyvinylchloride resins.
An example of formula for the composite materials is as follows:
Polyvinylchloride: 100 parts micaceous aluminum powder: 5 - 70 1~255~i) metal powder other than aluminum powder 0 - 145 plasticizer: as needed stabilizer: as needed However, the total amount of micaceous aluminum powder a~ powder other than aluminum powder must not be over lS0 parts.
An amount of micaceous aluminum powder of less than
5 parts is undesirable because it causes the coating composi-tion to be inferior in weatherability and corrosion resistance.
An amount of more than 70 parts is undesirable because coating composition is inferior in formability. Moreover, a total amount of metal powder of more than lS0 parts is undesirable because the resultant composite material coating is inferior in formability. The amount of plasticizer and stabilizer is added to impart good formability and durability.
Next, the composition and function of the acrylic-type resin film, which is a preferred embodiment, will be discussed.
The acrylic-type resin film may be comprised of one of the following composition Nos. 1 to 4, employing one or more of the following components A, B and C.
Component A = Cl - C4 alkyl methacrylate.
Component B ~ Cl ~ C8 alkyl acrylate.
Component C = ethylene-type monomer which is capable of being copolymerized with A and B.
Composition No. 1 mainly consists of the polymer of A.
Composition No. 2 mainly consists of a blend of polymers A and B.
Comp~sition No. 3 mainly consists of the copolymer of A and B.
Composition No. 4 mainly consists of the copolymer of A, B and C.
Composition Nos. 1 to 4 rnay contain additives such as ultraviolet absoxbers, pigment etc. The acrylic-type resin film is 20 to 200 ~m in thickness.
Next the process for obtaining the coated metal sheets of the present invention will be described.
Hot dip galvanized steel sheet, electrogalvanized steel sheet or electrolytic chromate treatment steel sheet etc. are used as the substrate steel sheet. Well-known adhesive for polyvinylchloride-metal laminated steel, which is of the acrylic-type, epoxy-type, urethane-type or rubber-type etc., is used as adhesive. The substrate steel sheet is precoated with adhesive, baked by heat treatment, and covered with the composite materials by coating or laminating.
In case of coating, the coating composition is used as a paste of suitable viscosity. The substrate steel sheet with adhesive is coated with this composition by roll coating, dipping, knife coating, or curtain coating etc., and then baked by heat treatment at 150C to 250C for gelation and adhesion.
In case of laminating, the composite material is first formed as film or sheet by calendering, extrusion etc.
Then, the substrate steel sheet with adhesive is heated, laminated with this film by a roll press or the like and then the resultant product is heated at 150C to 250C to insure adhesion.
The coated metal sheet of the present invention - is produced by the process described above.
_5_ 1~2~5~
The coated metal sheet may be overlaid with an acrylic-type resin film, which is a preferred embodiment of the present invention, as follows. After the substrate steel sheet i9 covered with the composite materials as described above, it is overlaid with acrylic-type resin film by a roll press etc. at 100C to 250C9 and then in certain cases, is heated at 100C to 250C for the purpose of improving adhesion.
The detailed effects of the present invention will now be explained taking into account the following practical, non-limitative examples.
Example l An electrolytic chromate treatment steel sheet of 0.5 mm thickness(Trademark: Hi-Top) was coated with an epoxy-type adhesive to a S ~m thickness by means of a bar coater, after which it was heated in a hot-air oven for 30 seconds at 300C. The temperature of the steel sheet was 230C. Then the steel sheet was cooled, coated with the composite materials at 200 um thickness by means of a knife coater and baked in a hot-air oven for 60 seconds at 260C.
The temperature of the steel sheet was 200C Then the steel sheet was cooled.
The composition of the composite material was as follows, the parts being given by weight:
polyvinylchloride resin (Trademark: Geon 12LL):
lO0 parts micaceous aluminum powder (0.5 ~m thickness) :
20 parts plasticizer (n-D.O.P.) : 50 parts stabiLizer (Cd-Ba -type) : 3 parts diluent (mineral spirits) : lO pàrts S5C~
The Dupont impact test (1/2" x 1 Kg x 50 cm) was applied to this coated steel shee-t. This coated steel sheet showed no evidence of adhesion loss and cracking of the coated layer. Also, this coated steel sheet was subjected to an outdoor exposure test and the steel sheet did not show adhesion loss and degradation such as discoloration and cracking of the coated layer, even after 8 years.
On the other hand, a reference sample, which was coa-ted with a composition wherein titanium white was used in place of micaceous aluminum powder, was greatly spoiled after S years of an outdoor exposure test and showed slight adhesion loss and discoloration of the coated layer after 3 years.
Next, an aluminum rich paint consisting of aluminum powder and an epoxy-type resin binder was coated on an elec-trolytic chromate treatment steel sheet to about 200 jum thickness. This coated steel sheet was subjected to outdoor exposure tests as a reference sample. This sample showed slightly spotty rust after about 2 years and showed red rust over the whole surface after 5 years. Also this sample was subjected to the Dupont impact test (1/2" x 1 Kg x 50 cmj, but showed cracking and adhesion loss of the coated layer.
Example 2 To the coating composition of Example 1, 50 parts by weight of lead powder of 10 ,um particle diameter was added.
The coated steel sheet obtained was essentially the same as that of Example 1. This coated steel shee-t showed no adhesion loss and cracking of the coated layer after Dupont impact test (1/2" x 1 Kg x 50 cm). Further, this coated steel sheet showed no adhesion loss and degradation such as discoloration and cracking in the coated layer after an outdoor exposure l~ZS.S~6~
test for 10 years.
Example 3 A composite coated steel sheet was produced as in Example 1. When the temperature of this sample was about 180C, this sample was overlaid with a blue acrylic-type resin film of 30 ~m thickness by press rolling, and heated in hot air oven for 60 seconds at 260C. The temperature of this sample was about 200C. Then this sample was cooled.
This sample was subjected to the Dupont impact test (1/2" x 1 Kg x 50 cm). This sample showed no evidence of adhesion loss and cracking of the coated layer. Also, after this sample was cross-hatched on the coated layer by means of a razor and was found to have a coating depth of 8 mm by the Erichsen test, the sample was subjected to the accelerated weathering test (Sunshine Weather Meter Test) JIS A 1415.
These samples showed no evidence of cracking, discoloration, blister and adhesion loss of coated layer after 8000 hrs. Then, the cross-hatched sample was subjected to the salt spray test JIS Z 2371 for 300 hrs. The length of delamination of the coated layer was under 1 mm.
On the other hand, a reference sample using titanium white as in Example 1 was overlaid with a blue acrylic-type resin film~of 30 ~m thickness.
This reference sample was subjected to the same tests. In Sunshine Weather Meter test, this reference sample showed slight unevenness of the surface and blistering of 3 to 100 mm length after 8000 hrs. In the salt spray test, this reference sample showed delamination of 7 to 17 mm length and red rust.
An amount of more than 70 parts is undesirable because coating composition is inferior in formability. Moreover, a total amount of metal powder of more than lS0 parts is undesirable because the resultant composite material coating is inferior in formability. The amount of plasticizer and stabilizer is added to impart good formability and durability.
Next, the composition and function of the acrylic-type resin film, which is a preferred embodiment, will be discussed.
The acrylic-type resin film may be comprised of one of the following composition Nos. 1 to 4, employing one or more of the following components A, B and C.
Component A = Cl - C4 alkyl methacrylate.
Component B ~ Cl ~ C8 alkyl acrylate.
Component C = ethylene-type monomer which is capable of being copolymerized with A and B.
Composition No. 1 mainly consists of the polymer of A.
Composition No. 2 mainly consists of a blend of polymers A and B.
Comp~sition No. 3 mainly consists of the copolymer of A and B.
Composition No. 4 mainly consists of the copolymer of A, B and C.
Composition Nos. 1 to 4 rnay contain additives such as ultraviolet absoxbers, pigment etc. The acrylic-type resin film is 20 to 200 ~m in thickness.
Next the process for obtaining the coated metal sheets of the present invention will be described.
Hot dip galvanized steel sheet, electrogalvanized steel sheet or electrolytic chromate treatment steel sheet etc. are used as the substrate steel sheet. Well-known adhesive for polyvinylchloride-metal laminated steel, which is of the acrylic-type, epoxy-type, urethane-type or rubber-type etc., is used as adhesive. The substrate steel sheet is precoated with adhesive, baked by heat treatment, and covered with the composite materials by coating or laminating.
In case of coating, the coating composition is used as a paste of suitable viscosity. The substrate steel sheet with adhesive is coated with this composition by roll coating, dipping, knife coating, or curtain coating etc., and then baked by heat treatment at 150C to 250C for gelation and adhesion.
In case of laminating, the composite material is first formed as film or sheet by calendering, extrusion etc.
Then, the substrate steel sheet with adhesive is heated, laminated with this film by a roll press or the like and then the resultant product is heated at 150C to 250C to insure adhesion.
The coated metal sheet of the present invention - is produced by the process described above.
_5_ 1~2~5~
The coated metal sheet may be overlaid with an acrylic-type resin film, which is a preferred embodiment of the present invention, as follows. After the substrate steel sheet i9 covered with the composite materials as described above, it is overlaid with acrylic-type resin film by a roll press etc. at 100C to 250C9 and then in certain cases, is heated at 100C to 250C for the purpose of improving adhesion.
The detailed effects of the present invention will now be explained taking into account the following practical, non-limitative examples.
Example l An electrolytic chromate treatment steel sheet of 0.5 mm thickness(Trademark: Hi-Top) was coated with an epoxy-type adhesive to a S ~m thickness by means of a bar coater, after which it was heated in a hot-air oven for 30 seconds at 300C. The temperature of the steel sheet was 230C. Then the steel sheet was cooled, coated with the composite materials at 200 um thickness by means of a knife coater and baked in a hot-air oven for 60 seconds at 260C.
The temperature of the steel sheet was 200C Then the steel sheet was cooled.
The composition of the composite material was as follows, the parts being given by weight:
polyvinylchloride resin (Trademark: Geon 12LL):
lO0 parts micaceous aluminum powder (0.5 ~m thickness) :
20 parts plasticizer (n-D.O.P.) : 50 parts stabiLizer (Cd-Ba -type) : 3 parts diluent (mineral spirits) : lO pàrts S5C~
The Dupont impact test (1/2" x 1 Kg x 50 cm) was applied to this coated steel shee-t. This coated steel sheet showed no evidence of adhesion loss and cracking of the coated layer. Also, this coated steel sheet was subjected to an outdoor exposure test and the steel sheet did not show adhesion loss and degradation such as discoloration and cracking of the coated layer, even after 8 years.
On the other hand, a reference sample, which was coa-ted with a composition wherein titanium white was used in place of micaceous aluminum powder, was greatly spoiled after S years of an outdoor exposure test and showed slight adhesion loss and discoloration of the coated layer after 3 years.
Next, an aluminum rich paint consisting of aluminum powder and an epoxy-type resin binder was coated on an elec-trolytic chromate treatment steel sheet to about 200 jum thickness. This coated steel sheet was subjected to outdoor exposure tests as a reference sample. This sample showed slightly spotty rust after about 2 years and showed red rust over the whole surface after 5 years. Also this sample was subjected to the Dupont impact test (1/2" x 1 Kg x 50 cmj, but showed cracking and adhesion loss of the coated layer.
Example 2 To the coating composition of Example 1, 50 parts by weight of lead powder of 10 ,um particle diameter was added.
The coated steel sheet obtained was essentially the same as that of Example 1. This coated steel shee-t showed no adhesion loss and cracking of the coated layer after Dupont impact test (1/2" x 1 Kg x 50 cm). Further, this coated steel sheet showed no adhesion loss and degradation such as discoloration and cracking in the coated layer after an outdoor exposure l~ZS.S~6~
test for 10 years.
Example 3 A composite coated steel sheet was produced as in Example 1. When the temperature of this sample was about 180C, this sample was overlaid with a blue acrylic-type resin film of 30 ~m thickness by press rolling, and heated in hot air oven for 60 seconds at 260C. The temperature of this sample was about 200C. Then this sample was cooled.
This sample was subjected to the Dupont impact test (1/2" x 1 Kg x 50 cm). This sample showed no evidence of adhesion loss and cracking of the coated layer. Also, after this sample was cross-hatched on the coated layer by means of a razor and was found to have a coating depth of 8 mm by the Erichsen test, the sample was subjected to the accelerated weathering test (Sunshine Weather Meter Test) JIS A 1415.
These samples showed no evidence of cracking, discoloration, blister and adhesion loss of coated layer after 8000 hrs. Then, the cross-hatched sample was subjected to the salt spray test JIS Z 2371 for 300 hrs. The length of delamination of the coated layer was under 1 mm.
On the other hand, a reference sample using titanium white as in Example 1 was overlaid with a blue acrylic-type resin film~of 30 ~m thickness.
This reference sample was subjected to the same tests. In Sunshine Weather Meter test, this reference sample showed slight unevenness of the surface and blistering of 3 to 100 mm length after 8000 hrs. In the salt spray test, this reference sample showed delamination of 7 to 17 mm length and red rust.
Claims (10)
1. A composite coated metal sheet comprising a metal sheet substrate coated with a composition which comprises about 100 parts by weight of polyvinylchloride resin and 5 to 70 parts by weight of micaceous aluminum powder.
2. The coated metal sheet of claim 1, wherein the coating further comprises at least one other metal powder selected from the group consisting of zinc, tin and lead and alloys of said metals, the total amount of micaceous aluminum powder and said other metal powder being 5 to 150 parts by weight.
3. The coated metal sheet of claims 1 or 2, which further comprises a top layer of an acrylic-type resin film of 20 to 200 µm thickness.
4. The coated metal sheet of claims 1 or 2 wherein said coating composition further comprises a plasticizer or a stabilizer or both.
5. Process for producing a composite coated metal sheet which comprises providing a composition comprising about 100 parts by weight of polyvinyl chloride resin and about 5 to 70 parts by weight of micaceous aluminum powder, applying said composition to a metal sheet substrate, and heating said composition on said metal sheet substrate to form a solid coating thereon.
6. Process according to claim 5, which comprises forming a paste of said composition, applying said paste to said metal sheet substrate and baking said paste on said metal sheet to form a solid coating thereon.
7. Process according to claim 5, which comprises forming a film or sheet from said composition, laminating said film or sheet on said metal sheet substrate.
8. Process according to claims 5, 6 or 7 wherein an adhesive is applied to said substrate before coating is applied.
9. Process according to claim 6, wherein said paste is baked on said metal sheet substrate at a temperature between about 150°C and 250°C.
10. Process according to claim 7, wherein the laminated product is heated at a temperature between about 150°C and 250°C.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA342,573A CA1125590A (en) | 1979-12-24 | 1979-12-24 | Composite coated metal sheet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA342,573A CA1125590A (en) | 1979-12-24 | 1979-12-24 | Composite coated metal sheet |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1125590A true CA1125590A (en) | 1982-06-15 |
Family
ID=4115900
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA342,573A Expired CA1125590A (en) | 1979-12-24 | 1979-12-24 | Composite coated metal sheet |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1125590A (en) |
-
1979
- 1979-12-24 CA CA342,573A patent/CA1125590A/en not_active Expired
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| MKEX | Expiry |