US20010009718A1 - Polymeric coated metal strip and method for producing same - Google Patents

Polymeric coated metal strip and method for producing same Download PDF

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Publication number
US20010009718A1
US20010009718A1 US09/767,785 US76778501A US2001009718A1 US 20010009718 A1 US20010009718 A1 US 20010009718A1 US 76778501 A US76778501 A US 76778501A US 2001009718 A1 US2001009718 A1 US 2001009718A1
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US
United States
Prior art keywords
strip
coated
set forth
polymer
extrudate
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.)
Abandoned
Application number
US09/767,785
Other languages
English (en)
Inventor
John Sinsel
Ralph Wilkerson
Eugene Chelen
James Velliky
Jyhwen Wang
Mark Loen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Weirton Steel Corp
Original Assignee
Weirton Steel Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority to US09/767,785 priority Critical patent/US20010009718A1/en
Priority to AU2001231076A priority patent/AU2001231076A1/en
Priority to EP01903231A priority patent/EP1409153A2/de
Priority to PCT/US2001/002161 priority patent/WO2001053004A2/en
Application filed by Weirton Steel Corp filed Critical Weirton Steel Corp
Assigned to WEIRTON STEEL CORPORATION reassignment WEIRTON STEEL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHELEN, EUGENE, LOEN, MARK V., SINSEL, JOHN A., VELLIKY, JAMES E., WANG, JYHWEN E., WILKERSON, RALPH
Publication of US20010009718A1 publication Critical patent/US20010009718A1/en
Priority to US10/156,471 priority patent/US7452434B2/en
Priority to US10/191,411 priority patent/US20030031859A1/en
Priority to US10/818,167 priority patent/US7419560B2/en
Priority to US10/841,723 priority patent/US7553389B2/en
Priority to US12/494,655 priority patent/US20090263672A1/en
Abandoned legal-status Critical Current

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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
    • B05D1/265—Extrusion coatings
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    • B05D3/08—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by flames
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    • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
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    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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    • B05D3/14—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by electrical means
    • B05D3/141—Plasma treatment
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Definitions

  • the present invention provides a novel polymeric coated strip metal and a method for producing same and in particular to a method in which the polymeric coating is extruded onto at least one side of a moving strip of metal, preferably steel.
  • a number of processes have been proposed for laminating metal sheet.
  • a laminate metal sheet is described having a noncrystalline polyester film adhered to at least one of its major surfaces.
  • a polyethylene terephthalate polyester material is use to form a film which is laminated to a metal sheet heated to a temperature above the polyester film such that the outer surface of the film remains above the melting point of the film during lamination and, thereafter, reheating the laminate to a temperature above the melting point of the film for a period of time and then rapidly quenching the polyester coated metal to below the glass transition point of the resin.
  • the present invention comprises a novel coated strip composite and method for making same.
  • the method includes the steps of pretreating a continuous metal strip with an oxidizing flame treater.
  • the flame pretreatment is juxtiposed with the strip uncoiler.
  • placing the flame pretreatment adjacent the uncoiler may have the advantage of reducing the space required for the coating process rolls and extruders.
  • the strip is pretreated with the Corona Discharge first and then flame pretreated.
  • the strip passes through a corona discharge unit.
  • the corona unit is placed ahead of the respective extruder.
  • a polymeric coating is applied to the two sides in two steps. In the first step, the surface to be coated is subjected to an oxidizing flame treatment, but the second side is subjected only to the corona discharge.
  • both sides of the strip are subjected to an oxidizing flame and a corona discharge prior to the extrusion coatings being applied.
  • the coatings are applied by a polymeric extruder and die located just after a nip roll on the processing line.
  • the extruder can be a single or double screw as is well known in the art.
  • the extrusion temperature for polypropylene pellets for example is 575 to 585° F., but as clear to those skilled in the art, the temperature will vary depending upon the resin used for the coating and coloration pigments admixed to provide a colored coating.
  • a chill roll preferably at a temperature substantially less than the extrudate temperature. For example, in certain high speed operations., e.g., 500 to 1500 feet per minute, temperatures of from about 150 to 170° F. are preferred for polypropylene.
  • the strip After the reheat treatment, approximately 1 to 15 seconds, the strip is passed through a quench tank comprising fluid maintained at a temperature of 40° to 120° F. The temperature depends upon the polymer. The initial quench fluid contact with the coated strip is maintained in laminar flow condition. Thereafter the strip can be dried and gauged prior to recoiling or subsequent processing or application forming or drawing.
  • FIG. 1 is a diagrammatic view of a process coating line in accordance with the present invention.
  • FIG. 2 is an exploded diagrammatic view of a typical extruder used in lines shown in FIGS. 1 and 2;
  • FIG. 3 is a diagrammatic view of another embodiment of a coating line in accordance with the present invention.
  • the present invention comprises coating processing line 10 having an uncoiler 12 for uncoiling a strip 11 of metal, such as steel, tinplate, chromium-coated steel, electrogalvanized, etc. While shown in FIGS. 1 and 3, various steering and bridle rolls will not be described or discussed in detail. Such rolls are placed where necessary and well known by those skilled in the art and form no part of the invention described herein.
  • a flame treater 13 for example, a Flynn burner, is positioned downstream of uncoiler 12 .
  • Flame treatment can be applied to either non-coated side of the strip but preferably to the side of the strip to be extrusion coated.
  • strip 11 then enters a Corona discharge, for example, an Enercon Corona, which further pre-treats the side of the strip to be extrusion coated with from 5 to 30 watts/ft 2 /min. and preferably about 6 watts/ft 2 /min.
  • a Corona discharge for example, an Enercon Corona, which further pre-treats the side of the strip to be extrusion coated with from 5 to 30 watts/ft 2 /min. and preferably about 6 watts/ft 2 /min.
  • strip 11 is entrained over rollers to position the strip so that one of its surfaces is juxtaposed to a first extruder 15 having die 16 for extruding the melted polymer on to the strip surface.
  • the strip is typically at ambient temperature or slightly above that when it enters the extruder die area; preheating is not required.
  • Die 16 is positioned so that the melt curtain exiting the die drops vertically into the nip area between the moving strip 11 and chill roll 18 such that the melt film contacts the moving strip just prior to contacting the chill roll.
  • Nip roll 17 defines the strip/chill roll nip area and functions to apply sufficient pressure to the moving strip (and thus to the chill roll through the melt film) to effect intimate contact of the melt film with the moving strip.
  • This nip roll can be covered with any number of durable rubber coatings but preferably neoprene with a hardness between 80 and 90 durometer but preferably 85-90.
  • the nip roll may also be chrome coated steel roll.
  • One or more extruders may be utilized to apply one or more layers of polymer coating in sequence or simultaneously.
  • Two hoppers implying two extruders per extruder/die station, are shown in FIG. 2.
  • stripper roll 20 which is designed to remove the coated strip from the chill roll after the melted coating is initially cooled by chill roll 18 .
  • the temperature of chill roll 18 is maintained between 100° and about 190° F. but preferably between 140° to 160° F. for a polymer leaving die 16 at a temperature of about 540° to 590° F.
  • strip 11 coated on the first side passes through an edge trimming operation and then is entrained over rolls to position the second uncoated side for treatment with a second flame treater 21 A and a second Corona discharge unit 21 and finally over nip roll 26 to a position adjacent to second extrusion station 25 and 26 .
  • flame treater 21 A is positioned preferably at 90° to the moving strip with an air/fuel mixture to achieve a preferable plasma value of from 37 to 42 and further pretreatment with Corona discharge unit 21 is accomplished at a preferred watt density of 6 watts/ft 2 /min.
  • strip 11 After passing through Corona discharge unit 21 , strip 11 enters extruder 25 and die 26 area where the second surface has applied thereto a polymeric coating. It may be desirable depending upon line length, speed of line, or other parameters, to provide the use of ovens to maintain the temperature of the first coated surface.
  • extruders 15 and 25 can be single or twin screw type extruders and can have additional hoppers and material feed systems for providing such additional components as a pigment concentrate for coloration of the coating, or polymers or copolymers either alone or as carriers for other components.
  • a number of different polymer resins have been used such as polypropylene, polyethylene, PET and the like.
  • various pigment concentrates such as polypropylene-based TiO 2 , and others have been used to provide coloration to the coating.
  • Other functional additives such as stabilizers, lubricants, nucleators, clarifiers, etc., have also been added to provide various chemical and physical property attributes.
  • strip 11 which is now coated on both sides with extrudate coating passes through an edge trimming operation and then through remelt oven 32 which is preferably an induction oven used to remelt the polymer coating to a temperature of from 265° to 650° F. but preferably between 470° to 490° F. for polypropylene.
  • remelt oven 32 which is preferably an induction oven used to remelt the polymer coating to a temperature of from 265° to 650° F. but preferably between 470° to 490° F. for polypropylene.
  • the polymeric or copolymeric coating tends to flow which provides somewhat of a leveling effect which enhances the surface finish through filling of voids and depressions in the original coating. It is also this treatment which is responsible for development of final adhesion characteristics of the coating to the strip.
  • pressure rolls can also be used to adjust the coating thickness and/or surface finish or enhance the adhesion of the coating prior to quenching.
  • the hot strip can pass through gauge rollers or
  • the reheated strip 11 is then directed to quench facility 34 in which a fluid such as water or other compatible heat transfer fluid is used to cool the polymer/strip combination. It is preferable for the heat transfer fluid to be directed to provide a laminar flow with respect to the strip moving therethrough in order to provide an enhanced polymer appearance and adhesion quality. It is desirable to provide a slight delay between the induction oven 32 and quench 34 of between 1 and 15 seconds. However, it has been found to be adequate to use a delay of 1 to 5 seconds between reheating and quenching.
  • the temperature of the quench liquid is preferably about 35° to 120° F., preferably 60 to 80 F.
  • the coated strip 11 may then pass through a surface treatment station where the polymer surface is corona treated to allow for other finishing operations such as painting, decorating or lamination. The coated strip 11 is then recoiled onto coiler 38 .
  • Post-treatment consisted of heating the initially coated metal strip to a temperature of 485° F. followed by a 5 second delay prior to water quench using a laminar flow arrangement. Resulting coated products were subjected to various laboratory tests to determine chemical and physical properties as well as formability testing which resulted in the production of 307 sanitary ends and 110 ⁇ 307 shallow draw cans.
  • Coating trials were completed as described in Example #1 except the bulk layer consisted of random copolymer (RACO) and mixtures of RACO and polypropylene homopolymer, both with and without TiO 2 concentrate.
  • Substrates consisted of standard 75 pound per base box tin Free Steel TU Designation designated for the production of sanitary ends and 75 pound per base box tin Free Steel TU Designation (Special Hot Mill Practice) Tin Free Steel designated for use in the production of 0.5 and 1.0 pound tapered salmon cans. Ends and cans produced from these coated products were evaluated using enamel rater measurements and standard test pack analysis to determine coating integrity and performance with various food products.
  • Coating trials were completed as described in Example #1 except the bulk layer consisted of polypropylene homopolymer, random copolymer, medium impact copolymer, or a combination of these three plus one of several additives consisting of various clarifiers and nucleators to modify crystallization mechanisms for the coatings on food cans and sanitary ends subjected to processing (i.e., retort cooking) after packing.
  • Laboratory tests performed on shallow draw cans and sanitary ends produced from these coated materials consisted of retort @ 250° F. & 15 psi for 90 minutes followed by characterization in critical, stressed areas of the cans and ends using binocular microscopy as well as scanning electron microscopy (SEM).
  • Coating trials were completed as described in Example #1 except differential coatings, consisting polypropylene homopolymer on one side and polypropylene homopolymer plus TiO 2 concentrate on the other side, polypropylene homopolymer on one side and polypropylene homopolymer plus a commercial gold concentrate on the other side, and polypropylene homopolymer plus TiO 2 concentrate on one side and polypropylene homopolymer plus commercial gold concentrate on the other side.
  • Tin Free Steels consisting of 75 pound per base box Tin Free Steel TU Designation and 75 pound per base box Tin Free Steel TU Designation (Special Hot Mill Practice) Tin Free Steels were once again employed using flame and Corona discharge pretreatments in tandem and post-treatment of the applied coating at various temperature ranging from 450° to 485° F. depending on preestablished calibration for each specific coating with the emissivity measurement device.
  • Coating trials were completed as described in Example #1 except substrates utilized consisted of 65 pound per base box Tin Free Steel DR-7.5 Designation, 0.20 lb/Base Box Exlectrolytic Tinplate Coating and 65 pound per base box DR-8 Designation, 0.20 lb/Base Box Eltrolytic Tinplate Coating.
  • Pretreatment consisted of the use a flame, only, with no Corona discharge.
  • Initially coated products were post-treated at temperatures between 440° and 480° F. and resulting post-treated materials were evaluated using standard adhesion testing and test pack analysis. While presently preferred embodiments have been shown and described in particularity, the invention may be otherwise embodied within the scope of the appended claims.
  • Example #1 Coating trials were completed as described in Example #1 except 65 pound per base box Full Finished Blackplate was used as the substrate with applied coating consisting of those as defined in Example #4. Excellent coating adhesion characteristics were observed for this coated product when post-treated at 485° F. with a delay time of 5 seconds prior to laminar flow water quench.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
US09/767,785 2000-01-24 2001-01-23 Polymeric coated metal strip and method for producing same Abandoned US20010009718A1 (en)

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US09/767,785 US20010009718A1 (en) 2000-01-24 2001-01-23 Polymeric coated metal strip and method for producing same
AU2001231076A AU2001231076A1 (en) 2000-01-24 2001-01-23 Polymeric coated metal strip and method for producing same
EP01903231A EP1409153A2 (de) 2000-01-24 2001-01-23 Polymerbeschichtetes metallband und verfahren zur herstellung desselben
PCT/US2001/002161 WO2001053004A2 (en) 2000-01-24 2001-01-23 Polymeric coated metal strip and method for producing same
US10/156,471 US7452434B2 (en) 2000-01-24 2002-05-28 Methods and apparatus for surface preparation and dual polymeric layer coating of continuous-strip flat-rolled sheet metal, and coated product
US10/191,411 US20030031859A1 (en) 2000-01-24 2002-07-09 Processing and apparatus for production of engineered composite combining continuous-strip sheet metal and thermoplastic polymers
US10/818,167 US7419560B2 (en) 2000-01-24 2004-04-05 Extruded molten polymeric film bonding of solid polymeric film to flat-rolled sheet metal continuous strip
US10/841,723 US7553389B2 (en) 2000-01-24 2004-05-07 Methods and apparatus for production of composite-coated rigid flat-rolled sheet metal substrate
US12/494,655 US20090263672A1 (en) 2000-01-24 2009-06-30 Methods and apparatus for production of composite-coated rigid flat-rolled sheet metal substrate

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WO2004101839A3 (en) * 2003-05-07 2005-07-28 Isg Technologies Inc Methods and apparatus for production of composite-coated rigid flat-rolled sheet metal substrate
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DE102006057884A1 (de) * 2006-12-08 2008-06-12 Wieland-Werke Ag Verfahren zur Herstellung eines metallischen Leitungsrohrs mit fest anhaftender Kunststoffummantelung
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US20100218893A1 (en) * 2006-12-08 2010-09-02 Till Merkel Method for the production of a metallic line pipe with a firmly adhering plastic sheathing
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WO2013004449A3 (en) * 2011-07-07 2013-03-28 Nv Bekaert Sa An elongated element with a thermoplastic coating
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US11623792B2 (en) * 2016-05-20 2023-04-11 Constellium Neuf-Brisach Metalloplastic strip for rigid food packaging and manufacturing method
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WO2001053004A3 (en) 2002-01-10

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