NZ258749A - A polymer laminated metal and methods of forming the laminate - Google Patents

Description

New Zealand No. 258749 International No.

TO BE ENTERED AFTER ACCEPTANCE AND PUBLICATION Priority dates: 18.11.1993 Complete Specification Filed: 18.11.1993 Classification: (6) B32B15/08; F16L58/02.10; F16L9/147; B32B31/00 Publication date: 27 April 1998 Journal No.: 1427 NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION Title of Invention: Metal pipe with integrally formed liner and method of fabricating the same Name, address and nationality of applicant(s) as in international application form: W.E. HALL COMPANY, a US company of 471 North Newport Boulevard, No. 205, Newport Beach, California 92663, United States of America WO 95/13917 PCT/US93/11421 258 749 METAL PIPE WITH "INTEGRALLY FORMED LINER AND METHOD OF FABRICATING THE SAME Field of the Invention 5 The present invention relates generally to buried pipe for use in sewers, storm drains, pen stocks, culverts, and other low head applications, and more particularly to metal pipe with an integrally formed liner for use in corrosive and abrasive environments and 10 a method of fabricating the same.

Background of the Invention Metal pipe of both corrugated and spiral rib design is widely used for drainage, culverts and other similar 15 fluid conduits. Although susceptible to abrasion, steel pipe is preferred over concrete pipe and the like due to its comparatively high strength and low weight. These characteristics render metal pipe relatively inexpensive to manufacture, ship and handle while permitting its use 20 in applications requiring it to support substantial soil overburden. Further, in recent years a particular spiral ribbed steel pipe has been introduced by W.E. Hall Co., of Newport Beach, California, the assignee of the subject application, that possesses hydraulic efficiency 25 comparable to more costly concrete pipe as well as possesses superior structural capabilities for prolonged use in buried storm drain applications.

Since metal pipe is susceptible to corrosion, its use has heretofore been restricted primarily to culvert 30 and storm drain applications. In sanitary applications, i.e. sewer systems, corrosion causing sulfuric acid is formed from hydrogen sulfide generated by waste products. Such waste products and/or acid renders the use of steel pipe in sanitary applications impractical since it 35 rapidly deteriorates in the corrosive environment. As such, much heavier and more expensive concrete, lined concrete and/or vitreous clay pipe has traditionally been utilized for sanitary applications. Thus, although metal pipe is generally preferred because of its high strength and relatively low weight and cost, metal pipe has heretofore not been widely used in sanitary applications 5 due to its susceptibility to corrosion.

In recognition of these deficiencies, prior art attempts to allow the use of concrete pipe as opposed to vitreous clay pipe for large size sewer applications while reducing the susceptibility to corrosion of 10 concrete pipe have included: the installation of a thick corrosive-resistant plastic liner, and/or forming the inside of a concrete pipe with additional sacrificial concrete in the crown portion of the pipe.

Such prior art corrosion-resistant liners typically 15 comprise plastic inserts sized to be received within each concrete pipe section. Such liners are commonly cast within each pipe section. Subsequently after the pipe sections have been laid in place, adjacent liners are bonded together with the intention of forming a seal to 20 prevent corrosive fluids and gases from contacting the concrete pipe. Although such prior art concrete pipe/plastic liner solutions have proven generally suitable for large size sewer applications, the inherent high cost of such solutions has posed a severe impediment 25 in construction products. Further the useful life of such prior art sacrificial concrete pipe solutions is finite, which requires widespread rehabilitation over time thereby mandating tremendous expense in down line rehabilitation costs.

In recognition of the general inability of metal pipe and concrete pipe for sewer applications, in recent years plastic pipe has been introduced into the marketplace. Although such plastic pipe withstands degradation caused by the corrosive environment found in 35 sewer applications, its use has heretofore been primarily limited to small size sewer applications. In this regard, the structural integrity of plastic pipe is extremely limited such that in large size applications, the sidewall of such plastic pipe must be fabricated extremely thick or profiled to enable such plastic pipe to withstand compressive forces exerted in burial 5 applications. Due to the high cost of such plastic material, the use of such plastic pipe in large scale sewer applications has been economically unfeasible. Therefore, in view of the specific factors encountered in large scale sanitary sewer applications, nearly all such 10 applications have utilized costly concrete pipe having a sacrificial wall formed therein which significantly decay over prolonged use and thus will require costly rehabilitation and./or replacement over time.

In contrast to the waste product and/or acid 15 environment encountered in sanitary applications, metal pipe utilized for burial storm drain applications additionally encounters substantial problems associated with its operational environment. In relation to burial storm drain applications, wherein metal pipe is the 20 primary material candidate, long term exposure of the exterior of the metal pipe within the burial environment serves to corrode the exterior of the pipe while water and debris flowing through the interior of the metal pipe degrades the pipe through abrasion.

In an effort to prevent such corrosion effects, the interior of metal pipe has been lined with concrete in the hopes that a thicker lining would be more abrasion resistant and thereby resist deterioration and corrosion. However, there fails to exist any fail-safe means for 30 anchoring concrete to the interior wall of metal pipe. Consequently, pieces of the concrete lining inevitably become detached from the pipe. When combined with the continual abrading action occurring therein, this quickly destroys the protective concrete layer. Additionally, 35 concrete is susceptible to cracking and chipping as a result of mishandling, earth movement, and thermal stress. Such cracking and chipping results in corrosion of the steel surface in the vicinity of the chip or crack.

An alternative prior art approach to solving the corrosion and abrasion deficiencies of metal pipe for 5 storm drain applications has been to fabricate the metal pipe from plastic laminated steel sheet material. One such prior art product is known as Black-Klad™, a product of Inland Steel Company of Chicago, Illinois. Prior to rolling the steel sheet into a pipe section, one surface, 10 i.e. that surface which forms the inner pipe surface, is laminated with a polymer material such as a polyethylene compound. The thickness of such lamination is limited to approximately 0.010 inch and is intended to resist degradation caused by corrosion and abrasion. However 15 due to the comparatively thin thickness layer of plastic laminant, the laminant tends to wear through due to abrasion from sand, rocks, etc. and thereby expose the metal surface below. Further, during the pipe formation process, the thin laminant oftentimes is damaged due to 20 metal cold roll forming procedures.

Attempts to apply thicker laminations to such prior art products have heretofore resulted in greater blistering and separation of the polymer compound from the metal pipe particularly when the pipe is exposed to 25 flow applications. As such, the application of a protective polymer layer to metal pipe has heretofore been rendered ineffective.

Therefore because the prior art interior lining of metal pipes have proven susceptible to abrasion and 30 corrosion, and since abrasion resistant inert linings such as those constructed of concrete or an inert polymer material have failed to remain effectively anchored to the metal pipe walls, metal pipe has heretofore been unacceptable for use in sanitary applications such as 35 sewer drains.

As such, there exists a substantial need in the art for a sufficiently thick coating or lining which may be securely applied to metal surfaces to maintain the integrity thereof when the metal pipe is placed in a corrosive environment and to remain thereon without blistering during the pipe formation process. Further, 5 there exists a substantial need in the art for an improved metal pipe with an inert protective lining constructed of a polymer material such as polyethylene which would resist the attack of sulfuric acid as well as resist other forms of corrosion encountered in sewer 10 application. snuimnry of the Invention The present invention specifically addresses and alleviates the above referenced deficiencies associated 15 in the prior art. More particularly, the present invention comprises a metal pipe with an integrally formed liner for use in corrosive and abrasive environments. In the preferred embodiment of the present invention, the liner is comprised of .050 to .125 inch 20 thick high density polyethylene which is securely bonded to the metal pipe during fabrication.of the metal pipe. However, other polymers having corrosion resistant properties similar to polyethylene are likewise contemplated herein.

The liner is formed by applying a thin co-extruded film of ethylene acrylic acid and a polyethylene/ethylene acrylic acid blend to the metal pipe surface and subsequently extruding a comparatively thick layer of high density polyethylene thereover. The co-extruded 30 film is applied in a pre-treatment process to the sheets-metal, prior to roll forming corrugations or ribs in the sheet steel. The final relatively thick high density polyethylene layer is applied after the corrugations or ribs are formed in the sheet metal and either prior to or 35 subsequent to helically winding and forming the sheet steel into pipe sections. The co-extruded film is specifically formed to securely adhere to the surface of the sheet metal and provide an upper film or layer suitable for subsequent thermal bonding of a relatively thick layer of high density polyethylene. As such, the co-extruded film serves as a strong adhesive which 5 chemically bonds to the metal pipe and additionally forms a polyethylene base material suitable to enable the subsequent application of a relatively thick layer of high density polyethylene thereto. As such, present invention provides a smooth, hydraulically efficient 10 interior surface which is resistent to the corrosive action of sulfuric acid and the like as is typically encountered in sanitary applications. It is also highly resistant to abrasion caused by the flow of water-born debris such as dirt and gravel as is encountered in 15 culvert applications.

The process of forming the metal pipe of the present invention commences with the steps of prewashing the sheet metal to remove any residual oil and dirt. The sheet metal is subsequently bathed in an alkaline 20 solution to remove chromates and then rinsed. The alkaline bath and rinse are preferably repeated and the sheet metal is then etched with an etchant and then dried. Optionally, a primer coat of an adhesive may be then applied and the sheet metal is heated to cure for 25 particular applications. Preferably, a co-extruded polymer layer of ethylene acrylic acid and polyethylene/ethylene acrylic acid blend is subsequently applied over the metal or if used the primer coat to which it adheres. Subsequently, the pre-treated metal 30 sheet is cooled and coiled and then formed by conventional techniques to include corrugations or ribs..

Subsequently, the pre-treated and corrugated sheet metal is heated and a molten layer of polymer such as high density polyethylene is extruded unto the pre-35 treated sheet metal typically having a thickness of approximately .050 to .125 of an inch. Due to the polyethylene being applied at an elevated plasticized temperature, it securely thermally bonds to the co-extruded film layer previously applied to the sheet metal to provide a composite corrosion and abrasive resistant pipe. In the preferred embodiment, the application of 5 the relatively thick, high density polyethylene layer may be applied prior to forming the corrugated sheet metal into pipe lengths or alternatively just subsequent to forming into pipe lengths. Subsequently, the pipe sections are cooled and cut into desired lengths using 10 conventional techniques. Although disclosed in relation to specific application to pipe forming applications, the present invention is additionally applicable to other metal forming applications wherein chemical resistance of the fabricated metal product is required. 15 In addition to being thermally bonded to the co- extruded film layer, the relatively thick, high density polyethylene layer may be further secured to the sheet metal via the use of anchors captured within the tapered channels of the pipe and attached to the high density 20 polyethylene layer.

Various means for attaching the anchor to the high density polyethylene layer are contemplated. The high density polyethylene layer may be forced along with the anchor into the tapered channel such that the high 25 density polyethylene layer substantially surrounds the anchor and is captured within the tapered channel. The anchor is preferably comprised of a compressible polymer material such that it may be forced through the narrow opening of a tapered channel and then expand such that it 30 remains captured therein. Optionally, the anchor may comprise a hollow center extending substantially the entire length thereof to facilitate such compression. Alternatively, the anchor may comprise a high density polyethylene core substantially surrounded by a low 35 linear density polyethylene covering.

Alternatively, the anchor may first be disposed within the tapered channel and then the high density polyethylene layer applied to the co-extruded film layer as previously described. The anchor is then bonded or welded to the high density polyethylene layer. Those skilled in the art will recognize that various means, 5 i.e. thermal bonding and/or the use of chemical adhesives or bonding agents, are suitable for attaching the anchor to the high density polyethylene layer.

Alternatively, a layer of polyethylene may be attached to the anchor prior to the insertion of the 10 anchor into the tapered channel such that a portion of the polyethylene layer extends outward through the opening in the tapered channel whereby it may be thermally or adhesively bonded to the high density polyethylene layer.

Alternatively, the anchor may be formed to have an integral portion which extends through the opening of the tapered channel and to which the high density polyethylene layer may be thermally or adhesively bonded.

Alternatively, the anchor may be disposed within the 20 channel prior to forming the tapered sides of the channel wherein a narrowed opening is formed. The use of a non-compressible anchor material is thus facilitated and the likelihood of the anchor being undesirably pulled through the opening of the tapered channel is mitigated. 25 Alternatively, a non-tapered or rectangular channel may be provided and a complementary shaped anchor disposed therein prior to the application of the relatively thick, high density polyethylene layer. The rectangular anchor may be wound into the channel in such 30 a manner that it resists removal from the channel. For example, a substantially straight anchor material may be bent during the insulation process such that the tendency of the material to straighten forces it outward and thus deeper into the channel, thereby maintaining its position 35 therein.

Thus, various methods are provided whereby the relatively thick, high density polyethylene layer may be securely attached to the inner walls of sheet metal pipe to prevent delamination or blistering of the relatively thick, high density polyethylene layer. The use of anchors as discussed above thus further increases the 5 life and reliability of the metal pipe with integrally formed liner of the present invention and also expands the potential applications of such pipe by reducing the pipe's susceptibility to harsh environments such as those encountered in sewer and culvert applications. 10 These, as well as other advantages of the present invention will be more apparent from the following description and drawings. It is understood that changes in the specific structure shown and described may be made within the scope of the claims without departing from the IE spirit of the invention.

Brief Description of the Drawings Figure 1 is a perspective view of the exterior of a length of pipe constructed in accordance to the present 20 invention; Figure 2 is an enlarged cross-sectional view of the pipe wall of Figure 1 taken about lines 2-2 of Figure 1; Figure 3 is a flow diagram of the method of forming metal pipe with an integral liner of the present 25 invention; Figure 4 is a perspective view of the apparatus for forming the metal pipe with an integrally formed liner of the present invention; Figure 5 is an enlarged perspective view of the pipe 30 former of Figure 4; Figure 6 is an enlarged sectional view of the sheet metal after the ribs have been formed but prior to crimping; Figure 7 is a sectional view depicting the crimping 35 lock seam process; Figure 8 is a sectional side view depicting the blending of the liner over the crimped lock seam; Figure 9 is a flow chart of the pre-treatment, pre-coating process for bonding the co-extruded film layer to the sheet metal; Figure 10 is an enlarged cross-sectional view of a 5 portion of the liner and steel pipe showing the resultant co-extruded film layer and high density polyethylene layer liner formed on the interior of the pipe layer.

Figure 11a is a cross sectional side view of a tapered channel having a solid anchor comprised of a 10 single material disposed therein wherein the relatively thick, high density polyethylene layer has been forced into the tapered channel along with the anchor; Figure lib is a cross sectional side view of a tapered channel having an anchor comprised of a high 15 density polyethylene core and low linear density polyethylene covering disposed therein wherein the relatively thick, high density polyethylene layer has been forced therein as in Figure 11a; Figure 11c is a cross sectional side view of a 20 tapered channel having a hollow anchor disposed therein wherein the relatively thick, high density polyethylene layer has been forced therein as in 11a; Figure 12 is a cross sectional side view of a tapered channel having an anchor disposed therein wherein 25 the anchor has been bonded to the relatively thick high density polyethylene layer; Figure 13 is a cross sectional side view of a tapered channel having an anchor disposed therein and having a polymer layer substantially surrounding the 30 anchor and extending from the opening of the tapered* channel such that the relatively thick high density polyethylene layer is bonded thereto; Figure 14 is a cross sectional side view of a tapered channel having an integral anchor and attachment 35 member wherein the anchor is disposed within the tapered channel and the attachment member extends through the opening thereof such that the relatively thick high density polyethylene layer attaches thereto; Figure 15 is a cross sectional side view of a non-tapered channel; Figure 16 is a cross sectional side view of a non- tapered channel having an anchor disposed therein; Figure 17 is a cross sectional side view of the channel and anchor of Figure 16 after the side walls of the channel have been tapered to capture the anchor 10 therein; and Figure 18 is a cross sectional side view of a non-tapered channel having a rectangular anchor disposed therein.

Detailed Description of the Preferred rerohnrt-iTnemt- The detailed description set forth belov in connection with the appended drawings is intended as a description of the presently preferred embodiment of the invention, and is not intended to represent the only form 20 in which the present invention may be instructed or utilized. The description sets forth the functions and sequence of steps for constructing and utilizing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or 25 equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

Although not by way of limitation, the process and apparatus of the present invention is well suited for use 31? on helical spiral ribbed metal pipe such as that disclosed in United States Letters Patent No. 4,838,317 issued to Andre et al. and assigned to the subject assignee W.E. Hall Co. In this regard, the process and apparatus of the present invention shall be described in 35 relation to the fabrication of such helical spiral ribbed metal pipe. However, those skilled in the art will recognize that the teachings of this invention are applicable to other metal pipe structures as well as other metal sheet products desired to withstand corrosive environments.

Referring now to Figures 1 and 2, the improved pipe 5 of the present invention is depicted generally comprised of a metal, preferably steel, spiral ribbed pipe 10 having externally extending ribs 12 formed thereon, lock seams 14, and an integrally formed polyethylene liner 16. Voids 18 are preferably formed between the liner 16 and 10 the sheet steel 11 of which the pipe 10 is formed as will be explained in more detail infra Referring now to Figure 3, an overview of the process of forming the metal pipe 10 with an integrally formed liner 16 of the present invention is provided. 15 The process generally comprises pre-treating sheet metal such as steel to have a thin co-extruded polymer layer formed thereon and coiling the same for further fabrication. The pre-treated sheet metal 11 is then uncoiled via e.n uncoiler 20, and ribs and/or corrugations 20 and seams 14 (as shown in Figures l and 2) are formed thereon with a profile roll former 22 (as shown in Figure 4). Subsequently the pretreated and preformed sheet metal 11 may be cleaned and heated 24. A sheet extruder and laminator 26 provides hot extrudate polymer 25 preferably high density polyethylene to the upper surface of the sheet metal. The laminator presses the hot extrudate into contact with the upper pre-treated surface of the sheet metal, thermally bonding it to the co-extruded film layer. The pipe and liner are then cooled 30 28 prior to being received by the roller and pipe former 30 which forms the flat sheet metal into a helical pipe section and crimps the seams 14 together to form a watertight seal. A cutter 32 then cuts sections of pipe to a desired length.

The steps of forming the ribs 12 and seams 14 with the profile roll former 22 and of forming the flat sheet metal into a helical pipe section with pipe former 30 are th or oughly disclosed in United States Letters Patent No. 4,838,317, issued to Andre, et al., the disclosure of which is expressly incorporated herein by reference. However, other conventional metal pipe fabrication 5 techniques as well as other fabricated metal products are contemplated herein.

As best shown in Figures 1 and 2, the metal pipe 10 having an integrally formed liner 16 of the present invention includes a channeled wall defining a plurality 10 of outwardly projecting structural ribs 12 and a hydraulically efficient interior stir face. The ribs 12 are preferably formed in a helical configuration and the channels 14 which are formed interiorly thereof are generally formed having either a square or generally 15 rectangular cross section and are open along the interior surface of the pipe.

Referring now to Figure 9, the detailed steps of the pre-treatment process 19 utilized prior to forming the sheet metal 11 into pipe sections 10 is described. Those 20 skilled in the art will recognize that the sheet metal is fabricated in elongate lengths that are coiled for ease in subsequent forming processes.

The initial pre-treatment process 19 is initiated by a pre-wash 62 being performed on the sheet metal 25 typically galvanized sheet steel to remove any residual oil and/or dirt from the upper and preferably lower surface of the sheet metal 11. This step may consist of processes well known in the art such as the application of a detergent, scrubbing with roller brushes, and 30 rinsing with water.

The sheet metal 11 is then subjected to an alkaline bath 64 to loosen and remove chromates formed upon the surface thereof. The alkaline bath 64 is followed by a rinse 66 which may be comprised of a buffer or 35 neutralizing acid. The alkaline bath 64 and rinse 66 are preferably repeated 68 and 70 to ensure adequate removal of chromates. After the alkaline baths 64 and 68 and the rinses 66 and 70, the sheet metal is subsequently subjected to an etchant such as a Parker Bonderite 1303 etchant to roughen its surface and prepare it for the application of a prime coat or layer. Next the sheet 5 steel is dried 74 and a prime coat 76 may be applied thereto. The prime coat preferably comprises a thin layer (approximately 1 to 2 mils.) of ethylene acrylic acid which is applied to the etched surface of the sheet metal 11. Optionally, after application, a primer coat 10 76 such as an adhesive may be applied and cured with heat to securely bond the primer coat 76 to the etched surface of the sheet metal 11. In most instances however, the primer coat 76 may.be eliminated as indicated in phantom lines in Figure 9.

Subsequently, the etched sheet metal 11 is heated 78 to approximately 400°F. and a relatively thin, continuous, planar co-extruded polymer layer is applied to the sheet metal 11. As best shown in Figure 10, the co-extruded polymer layer is preferably formed having a 20 thickness of approximately 10 mils, and is formed having a lower laminant layer 81 an upper laminant layer 82. In the preferred embodiment, the lower laminant layer 81 is formed of an ethylene acrylic acid which comprises an adhesive which securely bonds the co-extruded laminant 80 25 to the sheet metal 11 via direct contact with the sheet metal 11 or contact with the prime coat 76 applied to the sheet metal 11. The upper laminant layer 82 is preferably composed of_a_polymer/ethylene acrylic acid blend having a concentration of between 70% arid 98% 30 ethylene acrylic acid and 2% to 30% polymer such as an olefin which crosslinks with the polyethylene liner to be later applied to the sheet 11. As will be explained in more detail infra, the co-extruded layer 80 therefore provides a lower adhesive layer 81 adapted to securely 35 bond the co-extruded layer 80 to the sheet metal 11 and an upper polymer containing layer 82 which serves as a base material to allow thermal bonding of a subsequent polymer to the upper layer 82 of the co-extruded layer 80. Although not be way of limitation, in the preferred embodiment, the co-extruded layer 80 comprises a polymer co-extruded layer such as that manufactured by Dow 5 Chemical Company under the trademark PRIMACORE D.A.F. 624.

In the preferred embodiment, the co-extruded polymer layer 80 is applied to the sheet metal 11 at an elevated temperature of approximately 400°F. and is pressed 10 tightly thereupon by way of a conventional roller 83. Subsequently, the sheet metal 11 having the co-extruded polymer layer 80 applied thereto is cooled 84 and subsequently recoiled 85 for later use in the pipe fabrication process. In the preferred embodiment it is 15 contemplated that the pre-treatment process is facilitated on both the upper and lower surfaces of the sheet metal 11 with the lower surface treatment providing additional corrosion protection for the soil side of the resultant pipe. However the lower side may alternatively 20 be coated with conventional films such as epoxy for cosmetic purposes.

Referring now to Figures 4 and 5, the process of forming the metal pipe 10 with integrally formed liner 16 of the present invention is illustrated. As shown, the 25 pre-treated sheet metal 11 previously disposed in a coil 30 is mounted upon a conventional uncoiler 20. The uncoiler 20 facilitates the uncoiling of the pre-treated sheet metal 11, having the co-extruded polymer layer 80 disposed upon the upper surface thereof. The pre-treated 30 sheet metal 11 passes through a profile roll former 22 having a plurality of form rolls 32 which progressively form the ribs 12 (as shown in Figure 1) and edge seam members 54 and 56 (as shown in Figure 6) within the sheet metal 11. It should be noted that the formation of the 35 ribs 12 comprises the major cold forming procedures for the pipe 10 and is facilitated on the pre-treated sheet metal. As such the substantial tensile and compressive forces exerted in the cold forming process are accommodated by the relatively thin co-extruded polymer layer 80 without cracking and/or blistering. Upon exiting the profile roll former 22, the sheet metal 11 5 enters a cleaner/heater 24 which prepares the upper surface of the sheet metal 11 for the subsequent thermal bonding of the relatively thick polymer layer, preferably high density polyethylene thereto. Preferably the cleaner/heater 24 elevates the temperature of the sheet 10 metal 11 and the co-extruded polymer layer 80 disposed thereon to approximately 100 - 140° F. and not to exceed 180° F. such that the later applied substantially pure polyethylene layer will more readily thermally bond thereto.

A conventional plastic sheet extruder 26 having a screw assembly 34, extruder head 36, and a laminator 38 is preferably utilized to apply a relatively thick layer of polymer, preferably a high density polyethylene to the pre-treated and pre-formed sheet metal 11. As is well 20 known, the screw assembly 34 heats, plasticizes, and supplies a quantity of high density polyethylene to the extruder head 36. The extruder head 36 forms the polyethylene into a continuous planar layer 40 preferably having a thickness of approximately .050 to .125 of an 25 inch which is applied to the upper surface of the co-extruded polymer layer 80 disposed upon the sheet steel 11. In the preferred embodiment the polyethylene layer 40 is extruded unto the co-extruded polymer layer 80 at a temperature approximately 400° F. A laminator roller 30 preferably comprising a chilled roller 38 subsequently presses tho hot extrudate polyethylene layer 40 into contact with the co-extruded polymer layer 80 and the formed and cleaned sheet metal 11. Due to the high density polyethylene layer 40 being applied to the upper 35 surface of the pre-treated sheet metal 11 at an elevated plasticized temperature, a strong thermal bond is facilitated between the high density polyethylene layer 40 and the polymer constituent existing in the upper T.ayer 82 of the co-extruded polymer layer 80 disposed upon the sheet metal 11. As such, a polymer to polymer thermal bond is achieved which securely affixes the high 5 density polyethylene layer 40 to the pre-treated and preformed sheet metal 11. The resulting laminated sheet metal II may then be further cooled with blown air or water prior to being formed into a helical pipe section 46.

After application of the high density polyethylene layer 40 to the pre-treated sheet metal 11, the resultant metal/polyethylene laminate possesses a cross sectional configuration depicted in Figure 6. As shown, the high density polyethylene layer 40 extends in a thermally 15 bonded generally contiguous orientation over the upper surface of the sheet metal 11 and preferably overlaps the female edge seam 54 and male edge seam 56 formed on opposite edges of the sheet metal 11. Additionally, to facilitate superior hydraulics for the resultant pipe 10, 20 the layer 40 preferably bridges over the channel formed by the rib 12 of the sheet metal 11 forming voids 18 rendering a generally planar configuration to the high density polyethylene layer 40. Those skilled in the art however will recognize that the layer 40 may 25 alternatively be pressed into the voids 18 to be generally contiguous with the rigs 12 or alternatively the voids 18 may be filled with a polymer material if desired during the lamination process.

Subsequently, the thermally' bonded 30 metal/polyethylene sheet 44 is passed into a crimp/forming roller 50 wh; ch helically winds and crimps the male and female edge seams 56 and 54 into a lock seam which forms the resultant pipe length 46. The action of the crimping/forming roller 50 is depicted in Figure 7. 35 As shown in Figure 7, the crimping/forming rollers 50 crimps adjacent edge seam members 56 of laminated sheet metal 44 together by forcing male seam member 56 into the feinale seam member 54 of an adjacent turn as the sheet steel 44 is rolled helically and then bending both male 56 and female 54 seam members into laminar juxtaposition with the adjacent laminated steel sheet 11.

The crimping action of crimping/forming rollers 50 causes the high density polyethylene laminate 40 to be moderately displaced i.e. migrate away from the crimped edge seams 56 and 54, thereby pooling i.e. forming displaced polymer portions 59 adjacent the lock seam. 10 So as not to affect the hydraulic efficiency of the interior of the pipe 10, in the preferred embodiment, an additional roller 52 is provided which extends outwardly beyond the lock seam formed by the crimped edge seams 56 and 54 which causes the displaced polymer portions 59 to 15 be blended over forming a generally smooth configuration to the polymer 40 as shown in Figure 8. Subsequently, the polymer layer 40 may be cooled and subsequently cut to desired lengths via a conventional band saw, abrasive wheel, plazma, or laser pipe cutter 48.

As will be recognized the resultant pipe section 46 has substantial structural strength typical of conventional spiral ribbed metal pipe. Further, as shown in Figure 10, the pipe 10 includes an integrally formed substantially pure high density polyethylene liner 16 25 having sufficient thickness (i.e. approximately .100 of an inch) which is capable of withstanding corrosion caused by contaminant acids encountered in sewer applications. Additionally, since the high density polyethylene liner 16 is applied integrally to the pipe 30 during the fabrication process and thermally bonded to the co-extruded polymer layer 80 adhered to the steel pipe 11, delamination, blistering or cracking of the high density polyethylene layer 16 is eliminated. Further upon installation of the pipe 10 in sewer applications, 35 adjacent pipe sections may be easily abutted and joined at their interfaces by utilizing high density polyethylene wraps which may be thermally welded/bonded to the high density polyethylene liner affixed to the interior of the pipe.

As an additional embodiment of the present invention, it is contemplated that the application of the 5 relatively thick polyethylene layer 40 may be applied to the pre-formed and pre-treated sheet metal 42 subsequent l to all structural metal forming operations for the pipe 10. This additional embodiment is illustrated by the phantom lines in Figure 3 wherein the sheet extruder and 10 laminator 26 and subsequent cooling step is depicted in phantom lines and positioned after the seam roller and pipe formers s-eps 30. The processes for applying the high density polyethylene layer after all pipe forming procedures have been completed is identical to that 15 disclosed hereabove and has the additional advantage of avoiding any displacement of the high density polymer layer 40 due to the metal fabrication process.

Referring now to Figures 11a through 18, the relatively thick layer of high density polymer may be 20 further secured to the sheet metal substrate by capturing a preformed anchor within a tapered channel formed in the metal substrate and attached to the layer of high density polymer. The anchor is preferably comprised of a polymer material such as high density polyethylene and may 25 alternatively be comprised of a high density polyethylene core substantially covered by linear low density polyethylene. Alternatively, the anchor may comprise a substantially hollow core such that it is compressible and may therefore be more easily inserted through the 30 narrow opening of the tapered channel. The anchor is generally disposed within the tapered channel after the co-extruded layer has been applied and the channel has been completely formed. Alternatively, the anchor may be inserted in a heated plasticized state within the 35 interior of the channel as by way of extrusion techniques to completely fill the interior of the tapered channel.

With particular reference to Figure 11a a round anchor 104 is captured within a tapered channel 100. The anchor 104 is comprised of a compressible material and has been forced through the narrow opening 106 of the 5 tapered channel 100 after the relatively thick, high density polyethylene layer 102 has been applied to the sheet metal surface 103. Thus, a portion 108 of the high density polyethylene layer 102 has likewise been forced into the tapered channel 100 and is captured therein by 10 the anchor 104. In this manner, the high density polyethylene layer 102 has been further secured to the sheet metal surface 103 to mitigate the probability of delamination or blistering. With particular reference to Figure lib, the anchor 104 may alternatively be 15 comprised of a high density polyethylene inner core 132 surrounded by a linear low density polyethylene covering 134. The linear low density polyethylene outer covering is comparatively more compressible than the high density polyethylene inner core 132, thereby facilitating 20 compression of the anchor 104 during its insertion through the narrow opening 106 of the tapered channel 100.

With particular reference to Figure 11c, the anchor 104 may alternatively comprise a void or hollow core 130 25 to facilitate compression thereof during the insertion process.

With particular reference to Figure 12, the anchor 104 may be inserted into the tapered channel 100 prior to application of the relatively thick high density 30 polyethylene layer 102 to the sheet metal surface 103. The high density polyethylene layer 102 may subsequently be welded or aelhesively bonded to the anchor 104 forming a bond region 110. Those skilled in the art will recognize that various welding, e.g. thermal or 35 ultrasonic, processes are suitable and that various means of adhesively .bonding the anchor 104 to the high density polyethylene layer 102 are likewise suitable. The use of adhesive bonding requires application of the bonding material to the anchor 104 prior to application of the relatively thick high density polyethylene layer 102 to the steel surface 103. Attachment of the high density 5 polyethylene layer 102 to the anchor 104 thus further secures the high density polyethylene layer 102 in place.

With particular reference to Figure 13, the anchor 104 may be formed to have a film 112 of polymer, preferably polyethylene, substantially surrounding its 10 surface such that the anchor 104 and the surrounding portion of polyethylene film 112 may be inserted into the tapered channel 100 and a portion 114 of the polymer film 112 may extend through the narrow opening 106 of the tapered channel 100 such that the external portion 114 of 15 the polyethylene film 112 may be bonded to the relatively thick, high density polyethylene layer 102.

With particular reference to Figure 14, the anchor 104 may be formed to have an integral external portion 118, preferably connected thereto via a neck portion 122. 20 Thus, the anchor 104 may be forced through the narrow opening 106 of the tapered channel 100 such that the neck portion 122 extends through the narrow opening 106 and the external portion 118 remains disposed outside of the tapered channel 100 such that the high density 25 polyethylene layer 102 may be attached thereto.

Referring now to Figures 15 - 17, and alternative method of disposing the anchor 104 within a tapered channel is illustrated. Rather than forcing the anchor 104 through the narrow opening 106 of a preformed tapered 30 channel 100 as illustrated in Figures lla - 14, the anchor 104 may be disposed within the tapered channel 100 prior to the complete formation thereof.

With particular reference to Figure 15, prior to pinching the sides 126 of the tapered channel 100, the 35 channel is initially formed in the cross sectional configuration of a rectangle.

With particular reference to Figure 16, the anchor 104 is disposed within the rectangular channel 124. The anchor 104 may be easily disposed within the rectangular channel 124 without the need for compressing the anchor 5 104 because of the large size of the opening 125 of the rectangular channel 124. Thus, a non-compressible anchor may be utilized to mitigate the probability of the core being inadvertently pulled out of the channel.

With particular reference to Figure 17, subsequent 10 to disposing the anchor 104 within the rectangular channel 124 the sides 126 of the rectangular channel 124 are pinched together such that a narrow opening 106 is formed thereby, thus capturing the anchor 104 within a tapered channel 100. By disposing the anchor 104 within 15 the channel prior to crimping the sides 126 thereof, the step of forcing the anchor 104 through the narrow opening 106 of the tapered channel 100 is eliminated. After being so disposed within the tapered channel 100, the anchor 104 may be bonded to a subsequently applied layer 20 of high density polyethylene as described above.

Referring now to Figure 18, an alternative method for capturing an anchor within a channel is illustrated. A rectangular non-tapered channel 124 receives a complementary shaped anchor 128.. The anchor 128 is 25 preferably comprised of a linear resilient material which tends to maintain a straight configuration such that when bent it attempts to spring back into a generally straight configuration. The anchor 128 thus tends to push outward against the inner most surface of the bottom 136 of the 30 channel 124 as it attempts to straighten. That is, the anchor 128, when disposed within a channel 124 of a pipe is configured as a helix and attempts to straighten out by pushing outwards against the pipe.

The anchor 128 is disposed within the channel 124 35 prior to application of the relatively thick high density layer 102 to the sheet metal surface 103. After application of the high density polyethylene layer 102 the high density polyethylene layer is welded or adhesively bonded to the anchor 128 as described above.

It will be understood that the exemplary steel pipe with integrally formed liner described herein and shown 5 in the drawings represents only a presently preferred embodiment of the invention. Indeed, various modifications and additions may be made to such embodiment without departing from the spirit and scope of the invention. For example, various polymer materials 10 having properties similar to high density polyethylene and ethylene acrylic acid may be used. In this regard, in a broad sense, the present invention facilitates the use of a relatively thick polymer liner to be disposed upon a metal surface, which polymer is adhered to the 15 metal surface by way of a co-extruded layer having a lower most adhesive component and an uppermost polymer/adhesive component which enables the subsequent thermal bonding of the relatively thick substantially pure polymer layer via the constituent polymer layer 20 found in the uppermost layer of the co-extruded layer.

Additionally, the present invention contemplates the use of affixing a protective polymer layer to a fabricated product after pre-forming and/or completely forming the fabricated product by pre-treatment of the 25 metal utilized in the fabricated product for subsequent deposition of the polymer layer thereto. Also, various metals and alloys having sufficient structural strength may be utilized as the pipe material.

Furthermore, the polymer laminated metal and method 30 for forming the same need not be limited to the fabrication of pipe, but rather may find application in many diverse areas such as automotive body sheet metal applications and the like. Additionally, the anchors 104 need not. be round as described and illustrated, but 35 rather may be of any shape and configuration wherein they may be forced through the narrow opening of the tapered channel and subsequently expand to remain captured therein. Also, the tapered channels 100 need not be generally triangular in shape, but rather may be of any shape and configuration suitable for captviring the anchor therein and compatible with their use in a metal pipe or 5 other sheet mStal structure. Thus, these and other modifications and additions may be obvious to those skilled in the art and may be implemented to adapt the present invention for use in a variety of different applications.

Claims (20)

258749 WHAT I CLAIM IS:

1. A polymer laminated metal comprising: (a) a metal substrate; (b) a layer of polymer/adhesive blend formed upon said metal substrate; and (c) a layer of polymer thermally bonded to said layer of polymer/adhesive blend.

2. The polymer laminated metal of claim 1 further comprising a layer of adhesive formed intermediate said metal substrate and said layer of polymer/adhesive blend.

3. The polymer laminated metal of claim 2 wherein: (a) said layer of adhesive is comprised of ethylene acrylic acid; (b) said layer of polymer/adhesive blend is comprised of polyethylene/ethylene acrylic acid blend; and (c) said layer of polymer is comprised of polyethylene.

4. The polymer laminated metal of claim 3 wherein said layer of polyethylene/ethylene acrylic acid is comprised of at least 30% polyethylene.

5. The polymer laminated metal of claim 4 wherein said layer-ol polyethylene comprises high density polyethylene.

6. A method for forming polymer laminated metal, the method comprising the steps of: (a) applying a co-extruded polymer layer to metal substrate having a first layer formed of an adhesive and a second layer having an adhesive polymer/adhesive blend; and (b) thermally bonding a layer of substantially pure polymer to said co-extruded polymer layer. RECEIVED Intellectual Property Office .--<i FEB 1998 of New Zealand 258749

7. The method of claim 6 further comprising the step of heating at least one said co-extruded polymer layer and said polymer prior to the step of thermally bonding said layer of polymer to said co-extruded polymer layer.

8. The method of claim 7 further comprising the step of rolling said polymer against said co-extruded polymer layer.

9. The method of claim 8 wherein: (a) said co-extruded polymer layer comprises a layer of ethylene acrylic acid and a layer of polyethene/ethylene acrylic acid blend; and (b) the step of thermally bonding a layer of polymer to said co-extruded polymer layer comprises applying a layer of polyethylene to said layer of polyethylene/ethylene acrylic acid blend.

10. A method for forming polyethylene laminated metal, the method comprising the steps of: (a) washing said metal with a detergent to remove oil and particulate contaminants; (b) washing said metal with an alkaline solution to remove chromates; (c) rinsing said metal to remove said alkaline solution; (d) etching the surface of said metal to provide a rough surface; (e) heating said metal; (f) applying a co-extruded polymer layer to said metal; (g) applying a plasticized layer of polymer having a thickness greater than the thickness of said co-extruded polymer layer to said co-extruded polymer layer, and (h) cooling the polymer layer. JG 2.1 - 4 FEB 1998 of Now *Jand;258749;

11. A polymer laminated metal comprising:;(a) a metal substrate;;(b) at least one tapered channel formed in said metal substrate;;(c) a layer of polymer generally in laminar, juxtaposition to said metal substrate; and;(d) a preformed anchor disposed within said tapered channel to which said layer of polymer is attached.;

12. The polymer laminated metal of claim 11 wherein said preformed anchor is comprised of a polymer.;

13. The polymer laminated metal of claim 11 further comprising:;(a) a layer of adhesive formed upon said metal substrate;;(b) a layer of polymer/adhesive blend formed upon said layer of adhesive; and;(c) wherein said layer of polymer is bonded to said layer of polymer/adhesive blend.;

14. The polymer laminated metal of claim 12 wherein said preformed polymer anchor is comprised of:;(a) a high density polyethylene core; and;(b) a low density polyethylene covering surrounding said core.;

15. The polymer laminated metal of claim 11 wherein said layer of polymer has been urged into said tapered channel along with said preformed anchor such that said layer of polymer substantially surrounds said polymer anchor such that said polymer layer is captured within said tapered channel.;

16. The polymer laminated metal of claim 12 wherein said layer of polymer is bonded to said preformed polymer anchor.;-ST27 " 4 FEB 1998;25 8 7 A 9;m;

17. The polymer laminated metal of claim 12 wherein:;(a) said anchor further comprises a preformed layer of polymer attached thereto, a first portion of said anchor preformed polymer layer extending from eaid tapered channel and a second portion of said anchor preformed layer substantially surrounding said anchor and attached thereto; and;(b) said layer of polymer in laminar juxtaposition to said metal substrate is bonded to said first portion of said anchor preformed polymer layer.;

18. The polymer laminated metal of claim 12 wherein said anchor • further comprises a planar polymer member disposed in laminar juxtaposition to said metal substrate, said planar polymer member being attached to said preformed polymer anchor and being formed as an integral portion thereof.;

19. The polymer laminated metal of claim 11 wherein said preformed anchor further comprises a void extending substantially along the length of said anchor such that said anchor may be compressed as said anchor is being installed within said tapered channel.;

20. A method of forming a polymer laminated metal comprising the steps of:;(a) applying a co-extruded polymer layer to a metal substrate, said co-extruded polymer layer comprising a first layer of an adhesive and a second layer of adhesive/polymer blend; and i;(b) forming at least one tapered channel within said metal substrate;;(c) thermally bonding a layer of comparatively thick polymer to said co-extruded polymer layer, said comparatively thick polymer substantially covering said tapered channels;;(d) urging an anchor through said comparatively thick polymer and into said tapered channel such that said layer of;-4 FEB 1998;of N°w Zealand;25 8 74;comparatively thick polymer substantially surrounds said anchor such that said layer of comparatively thick polymer is captured within said tapered channel.;A method of forming a polymer laminated metal comprising the steps of:;applying a co-extruded polymer layer to a metal substrate, said co-extruded polymer layer comprising a first layer of an adhesive and a second layer of adhesive/polymer blend;;forming at least one tapered channel within said metal substrate;;disposing an anchor within said tapered channel;;thermally bonding a layer of comparatively thick polymer to said co-extruded polymer layer; and bonding said layer of substantially pure polymer to said anchor.;22. A method of forming a polymer laminated metal comprising the steps of:;applying a co-extruded polymer layer to a metal substrate, said co-extruded polymer layer comprising a first layer of an adhesive and a second layer of adhesive/polymer blend;;forming at least one tapered channel within said metal substrate;;disposing an anchor partially within said tapered channel, said anchor comprising a first portion which is disposed with said tapered channel and a second portion which is disposed in laminar juxtaposition to the metal substrate proximate said tapered channel; and bonding a comparatively thick polymer layer to said co-extruded layer and to the second portion of said anchor.;23. The method of claim 22 wherein said second portion of the anchor comprises a film of polymer substantially surrounding the first portion of said anchor and bonded thereto.;fntelleotuai Property Office;-33-^ FEB 1998;0f Now Zealand;(a);(b);(c);(d);(e);(a);• (b);(c);(d);2587 49;24. The method of claim 22 wherein said first and second portions of said anchor are formed as a single integral unit.;25. A method of forming a polymer laminated metal comprising the steps of:;' ';(a) applying a co-extruded polymer layer to a metal substrate, said co-extruded polymer layer comprising a first layer of an adhesive and a second layer of adhesive/polymer blend;;(b) forming at least one channel within said metal substrate;;(c) disposing an anchor within said channel;;(d) pinching in the upper portion of said channel to form a taper channel to capture said anchor therein; ,;(e) bonding a layer of comparatively thick polymer to said co-extruded polymer layer; and;(f) bonding said polymer layer to said anchor.;26. The method as recited in claim 25 wherein the steps of thermally bonding a layer of substantially pure polymer to said co-extruded polymer layer and of bonding said polymer layer to said anchor are performed simultaneously.;END OF CLAIMS W E HALL COMPANY;by their Attorneys;JAMES &WFTJ.S;-RECEIVED;intellectual Property Office;*-8r^o - 4 FEB 1998 of Now Zealand