CN1195623C - 高性能金属材料及其制备方法 - Google Patents

高性能金属材料及其制备方法 Download PDF

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CN1195623C
CN1195623C CNB008158045A CN00815804A CN1195623C CN 1195623 C CN1195623 C CN 1195623C CN B008158045 A CNB008158045 A CN B008158045A CN 00815804 A CN00815804 A CN 00815804A CN 1195623 C CN1195623 C CN 1195623C
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resin
ultraviolet curable
curable resin
metal materials
binding agent
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CN1390160A (zh
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J·H·帕森斯
N·J·巴斯比
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Corus UK Ltd
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Abstract

本发明提供一种高性能金属材料，包括：粘结有表面涂层的金属基体，该表面涂层包括紫外线固化树脂面层、透明的薄膜和粘结剂底层，底层被粘结到金属基体的表面上。还提供制造高性能金属的方法，包括：(i)感应加热金属基体材料至160℃到210℃；(ii)挤压多层复合薄膜，该薄膜包括透明的薄膜和具有紫外线固化树脂面涂层的粘结剂底层；(iii)在足以促使将粘结剂粘结到金属基体涂覆表面上的压力下，将(ii)的复合薄膜涂覆到步骤(i)的加热的金属基体上；和(iv)再将步骤(iii)的金属基体加热至180℃到240℃，保持足以完成将粘结剂粘结到金属基体涂覆的表面上的时间。

Description

高性能金属材料及其制备方法
技术领域
本发明涉及耐用金属材料。特别是，适于制造洗衣房和厨房用具及附件中使用的材料。
背景技术
钢是为人所知的耐磨且结构坚固的材料，常常用于提供家庭和饭店/餐馆中的厨房和洗衣房用具和附件的外壳或结构的基础。然而，当反复处于湿、热或腐蚀环境中时，钢的表面容易留下印记、生锈或者受到腐蚀。
为了避免这些问题，可以用相对惰性且不受潮、热或腐蚀环境影响的耐用塑料材料涂层设置在钢表面上。这样的塑料通常呈现出高光泽白的表面。偶而可能呈现其它颜色的表面，该表面可有大约5％着色变化和金属效果。
抛光金属表面闪亮的外观常常被视为清洁的标志，在准备和储存食物并洗涤餐具和器皿的厨房中，或者在洗涤和储存服装的洗衣房中，这是非常合乎需要的外观。
特别是在加工食物的厨房中，重要的是制备的表面器皿不含任何大的足以保持或截留食物颗粒或微生物的明显裂缝或缺陷，这些裂缝或缺陷会将污染物转移至食品准备区域或食物中。因此，极其需要提供具有能够方便擦干净的非常平滑耐划伤表面的用具和/或器皿。
有光泽的抛光金属表面是已知的，可以不锈钢的形式提供这样的表面。抛光时，这样的钢提供了非常合乎需要的有美感的外观，但要以可观的成本来制造。另外，这样的钢常常容易被粘的手指或水留下污记。已经通过不锈钢与抗污记层叠层来尝试减轻此污记问题。然而，这会增加早已昂贵的产品的成本，并且以前已经证明这样的叠层制品在湿、热或腐蚀环境中有分层的倾向。这可以通过标准试验方法证明，其中在洗涤液中煮沸叠层制品以模拟在这类环境中的长期使用。而且，叠层制品表面的抗划伤性能也未达到消费者的期望。
可以通过用锌或类似的阴极保护体系来为碳钢提供抗腐蚀性能，然而这样处理影响钢有美感的外观，生成的表面看起来是不希望的阴暗或无光泽。可以通过在有纹理(textured)的聚酯薄膜上气相沉积发光的金属表面，比方说铝来补救在美学要求方面的损失，但是此补救会再次导致潜在的分层问题。
发明内容
根据本发明，提供一种制造高性能金属材料的方法，包括：
(i)感应加热金属基体材料至约160℃到210℃；
(ii)挤压多层复合膜，该膜包括基本透明的薄膜，最外的紫外线固化树脂面涂层和将与金属基体材料接触的粘结剂底层。
(iii)在足以引发粘结剂粘结到金属基体涂覆表面上的压力下，将(ii)的复合薄膜施加到步骤(i)的加热的金属基体上；和
(iv)再将步骤(iii)的金属基体加热至约180℃到240℃一段足以完成将粘结剂粘结到金属基体涂覆的表面上的时间。
紫外线固化树脂，包括环氧树脂或丙烯酸系树脂，能为复合材料提供平滑、滑划份且基本上透明的外表面。可以通过加入一种或多种附加剂而改善耐刮表面的性能，例如增加表面的抗划伤性能的矿物填料或有机或无机滑爽剂。
可以有选择性地向表面涂层中的任何组分层中加入着色剂以提供各种有美感的外观。优选的是在涂覆表面涂层期间加入这样的着色剂。可以以在溶剂，例如酮或其它芳族或脂肪族烃中携带染料或颜料的形式提供着色剂。优选地，着色剂在制造复合薄膜期间与液体紫外线树脂混合，紫外线树脂辊涂到透明薄膜上并且固化。提供的颜色以花样或图像的形式出现在得到的叠层制品的表面上。
将基质和表面涂层再加热至高温为粘结剂良好的二次熔化，则提供了增强的粘结作用，并提供了改善的对基体表面的粘结。理想的是在某一最高温度下进行此再加热1秒至10秒，该最高温度低于表面涂层开始熔化、变形或变色的温度。
要按需选择表面涂层的组成层以使粘结剂在低于其它组分熔点的温度下熔化，优选地，透明薄膜层在低于紫外线固化树脂熔点的温度下熔化。
在根据本发明制造的金属材料中，通常对叠层制品的任何腐蚀都限于暴露的金属表面，在这种情况下仅限于在多层材料的切割边缘。粘结聚合物涂层对下面的任何薄膜腐蚀提供了保护，从而防止对装饰性表面的任何损伤或腐蚀。
本发明人已经发现，通过这种两段式方法，所提供的优越的粘结提供了比以前存在的相似品种的材料具有大得多的耐腐蚀性的高性能金属材料。该材料具有令人愉悦的在实际中容易保养的有美感的外观，能够形成复杂的形状以适应各种用具或附件的设计，并在湿、热和腐蚀条件(典型地是存在于家庭洗衣间和厨房中)下显示良好的耐腐蚀性能。
用这种方法制造的产品的其它应用包括用于办公家具或汽车内部的耐用、对美感有要求的材料。在这样的应用中，可以在表面涂层中提供各种效果、例如抛光的木制品效果。
理想的是在高于约180℃但低于210℃的温度下进行步骤(i)的加热过程。理想的是在约200℃到230℃之间，最理想的是在约210℃到230℃之间进行步骤(iv)的加热过程。
另一方面，本发明提供一种高性能金属材料，包括：粘结有表面涂层的金属基体；所述表面涂层包括紫外线固化树脂涂面层，基本透明的薄膜和粘结剂底层，该底层的粘结到金属基体的表面上。
适用于紫外线固化树脂的材料包括环氧树脂和丙烯酸系树脂，透明薄膜优选的是可挤压的塑料材料，例如：聚对苯二甲酸乙二醇酯(PET)，聚丙烯(PP)或聚氯乙烯(PVC)，最优选的是PET。透明薄膜可以简单地浇铸或双轴取向。
粘结剂理想的是聚合物，优选的是聚酯或聚烯烃，它们可以是无定形的或晶形形式的或这些形式的组合。特别优选的粘结剂是共挤出的聚酯共聚物。
可以有选择性地预处理金属基体以提供更有美感或抗腐蚀的表面，例如用电解钝化方法。使用这样的钝化方法可以极大地改善金属/聚合物结合的耐用性。
本发明的金属材料显示出以前只有阴极保护的钢才具有的性能特征，但是与那些钢不同，其制造相对廉价并且还显示出高光泽的美观外表。
附图说明
现在，将只参考所附示意图来举例描述本发明，其中图1说明根据本发明，将透明聚合物涂层涂覆到铬/氧化铬钝化钢带表面上的典型设备。
具体实施方式
图示设备包括厚度在0.05mm到0.5mm之间的钝化钢带2的带卷1，其在被辊引导至涂覆室5之前通过积蓄器(accumulator)3。当钢带2进入室5时，其通过感应加热器6，感应加热器将钢还加热到大约200℃的温度。在加热器6的下面设置两个对转辊7。辊可以具有抛光的表面或镜面。可以通过使用铬或镀铬辊而达到此光洁度。或者，可以使用硬橡胶(例如VITON)辊或具有硬橡胶表面的辊。
具有紫外线固化环氧树脂面涂层(top coat)的透明聚丙烯或聚对苯二甲酸乙二醇酯薄膜9的带卷8位于涂覆室5内。聚合物膜9的厚度优选的是在5到100微米之间，紫外线固化树脂涂层的厚度约为3微米。复合聚合物和紫外线固化树脂的典型厚度是15到25微米。
每种薄膜在两面中的一面上涂覆有粘结层。用来与钢基体接触的薄膜的那一面上是粘结层。粘结层含许多基本上透明的聚合物如聚烯烃或聚酯中的任何一种。
通过包括一系列拉紧(tensioning)和伸展(spreading)辊11的层合机(laminator)向加热的钢带处引导透明薄膜9，以保证薄膜9与钢带之间的界面没有皱纹、应力线和缺陷。
将膜层粘合到钢带上由辊7实现。辊压结合后，叠层钢带10通过约200℃-230℃温度下的二次加热炉4以完全熔化粘结层。选择二次加热温度要足够高以熔化粘结层，但不能高到足以熔化薄膜。在加热区4a使钢带维持在高温足够长的时间以完成粘结过程。
然后通过积蓄器12传送叠层钢带10到卷线机(coiler)14。可以在涂覆室5内设置一些强制冷却的装置，例如淬火槽4b。
通过此方法制造的叠层钢带通常包括0.05到0.5米厚的钢基体，约2微米厚的透明粘结层和具有1到5微米厚的紫外线固化树脂面涂层的10到100微米厚的透明聚对苯二甲酸乙二醇酯层。这样，聚合物膜作为腐蚀阻挡层而且紫外线固化树脂变成薄层不可分割的部分，提供了耐划伤的表面。

Claims (12)

1.一种制造高性能金属材料的方法，包括：
(i)感应加热金属基体材料至160℃到210℃；
(ii)挤压多层复合薄膜，该薄膜包括透明的薄膜，最外的紫外线固化树脂面涂层和将与金属基体材料接触的粘结剂底层；
(iii)在足以促使将粘结剂粘结到金属基体涂覆表面上的压力下，将(ii)的复合薄膜涂覆到步骤(i)的加热的金属基体上；和
(iv)再将步骤(iii)的金属基体加热至180℃到240℃，保持足以完成将粘结剂粘结到金属基体涂覆的表面上的时间。
2.如权利要求1中所述的方法，其中步骤(ii)中的紫外线固化树脂是环氧树脂。
3.如权利要求1中所述的方法，其中所述的紫外线固化树脂是丙烯酸树脂。
4.如权利要求1到3中任何一个所述的方法，还包括向紫外线树脂中加入附加剂以改善固化的紫外线树脂抗划伤性能的步骤。
5.如权利要求1至3中任何一个所述的方法，进一步包括向步骤(ii)多层复合薄膜中的一种或多种组分层中加入着色剂的步骤。
6.如权利要求1到3中任何一个所述的方法，其中，在步骤(iii)中通过橡胶压轧辊施加压力。
7.一种高性能金属材料，包括：粘结有表面涂层的金属基体，该表面涂层包括紫外线固化树脂面层、透明的薄膜和粘结剂底层，底层被粘结到金属基体的表面上。
8.如权利要求7中所述的高性能金属材料，其中紫外线固化树脂含提供改善固化树脂抗划伤性能的附加剂。
9.如权利要求7或权利要求8中所述的高性能金属材料，其中紫外线固化树脂是环氧树脂。
10.如权利要求7或8所述的高性能金属材料，其中紫外线固化树脂是丙烯酸树脂。
11.如权利要求7或8所述的高性能金属材料，其中透明的薄膜含聚对苯二甲酸乙二醇酯。
12.如权利要求7或8所述的高性能金属材料，其中粘结剂是共挤出的聚酯共聚物。
CNB008158045A 1999-11-19 2000-11-14 高性能金属材料及其制备方法 Expired - Fee Related CN1195623C (zh)

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