POLYMER/METAL LAMINATE AND METHOD FOR PRODUCING THE SAME

Abstract: Corrosion resistant impervious steel strip of a thickness of between 0.05 mm to 0.5 mm has bonded to at least one of its surfaces a layer of a polymer. Preferred polymers are polyethylene terephthalate and polypropylene. Polyvinyl chloride may also be used.

Description: POLYMER/METAL LAMINATE AND METHOD FOR PRODUCING THE SAME This invention relates to a laminated corrosion resistant steel strip and more especially to steel strip known commonly as "tin mill products". The invention also relates to methods of producing such steel strip and products produced therefrom. The term "tin mill products" includes steel strip and sheet (hereinafter referred to simply as "strip") subjected to a passivation or galvanising treatment. These products include electrolytic tin plate, electrolytic chromium/chromium oxide coated steel, and galvanised steel strip. These products are typically of a thickness between 0.05mm and 0.5mm. Electrolytic tinplate and electrolytic chromium/chromium oxide coated steel are produced by coating the surfaces of thin gauge low carbon mild steel strip (known as black plate), with impervious films of passive material by, for example, anodic or cathodic polarisation to reduce significantly the active state of these coated surfaces. Galvanised strip is produced by coating steel strip with a layer of zinc also to reduce significantly the active state of the coated surface or surfaces. With these processes, the thin gauge strip produced is resistant to corrosion. Electrolytic tinplate is a low carbon mild steel strip coated with tin by electrodeposition. The tin coating can be deposited equally or differentially on each strip surface in a range of thicknesses. Electrolytic chromium/chromium oxide coated steel strip (ECCS) is a low carbon, mild steel strip coated on both of its sides with a complex layer of chromium and chromium hydroxides applied by electrodeposition. Electrolytic steel strip is used predominantly in the packaging industry and galvanised strip is used in, for example, domestic appliances such as washing machines. Because of its relatively low weight compared with steel, aluminium has been favoured for many thin gauge laminated products where resistance to corrosion is important. These products include reflectors for light fittings. The relatively high cost of aluminium has, however, caused producers to seek alternative and less expensive strip products able to replicate the properties of aluminium. It is an object of this invention to provide a range of such alternative products. It is known to laminate polymer films onto sheets of aluminium for inter alia decorative and reflective purposes. Hitherto, attempts to laminate polvmer films onto steel have not been successful becauεe of problems in achieving a satisfactory bond capable of surviving, for example, forming and drawing operations. These problems have been overcome, or at least alleviated, in the present invention. Thus, the present invention sets out to provide laminated tin mill products coated by a passivation or galvanising process which have properties at least egual to those of conventional laminated aluminium strip products. The invention also sets out to provide methods of producing these laminated sheets. According to the present invention in one aspect there is provided corrosion resistant impervious steel strip of a thicknesε of between 0.05mm to 0.5mm to at least one surface of which is bonded a layer of a polvmer. Preferred polymers are polyethylene terephthalate and polypropylene. Polyvinyl chloride may also be used. The thickness of the pol mer layer may be between 10 and 100 microns. Preferred ranges of thickness are between 10 and 80 microns, 12 and 50 microns, and 12 and 25 microns. To minimise iridescence, a polymer layer thickness between 15 and 25 microns is preferred. The polymer layer may be coated with a film of metallic particles, examples of which include aluminium, silver, nickel or stainless steel, to provide a reflective surface therefor. A typical thickness of metallic coating is lOnm, although thicknesses of between 5nm and 50nm may¬ be employed. Coating may be achieved by vapour deposition or conventional sputtering techniques. A bonding promoter for providing an enhanced bond between the metallic coating and polymer iayer may be provided. The polymer layer may also include a bonding Iayer. This bonding layer may take the form of a coating applied to one surface of the polymer layer or the strip to which the polymer layer is to be applied. The melting point of this bonding iayer is preferably between 150°C and 230°C but should be below that of the polymer layer. A scratch inhibiting coating may be applied to one or both surfaces of the polymer layer. The corrosion resistant strip may be passivated. The passivation treatment may be an electrolytic treatment in which the passivating material may be tin, chromium, chromium oxide, potassium titanium oxalate, titanium sulphate, zirconium sulphate or a phosphate of chromium, potassium, titanium or zirconium. Alternatively the corrosion resistant strip may be steel strip coated with zinc by a galvanising process. Other passivation treatments may however be employed. It is a characteristic of tin mill products that they are work hardened and exhibit good weldability, formability, elongation and fabrication characteristics as exemplified by their wide use in the packaging industry. These characteristics when taken with steel's inherent tensile strength enable relatively thin gauge corrosion resistant steel strip having properties at least equivalent to those of aluminium to be employed for a range of products. In another aspect, there is provided a method of producing laminated corrosion resistant steel strip of a thickness between 0.05mm and 0.5mm, the method comprising coating black strip of this thickness with a corrosion resistant material by an electrodeposition or galvanising process and subsequently hot roll bonding to one or each surface of the strip a layer of a polymer selected from polyethylene terephthalate or polypropylene or polyvinyl chloride. The steel strip is typically heated to a temperature of the order of 160°C before it enrers the nip of a pair of contra-rotating rolls. The or each polymer layer is guided onto the or each side of the beared srrip as ir enters the roll nip and is bonded thereto. The invenrion will now be described by way of example only with reference to the accompanying diagrammatic drawings, in which:- Figure 1 illustrates typical appararus for applying polymer coatings ro rhe surfaces of sreel srrip in accordance wirh rhe invention; and Figures 2 and 3 are sections of laminated strip in accordance wirh the invention. The apparatus illusrrated in Figure 1 comprises a coil 1 of passivated steel strip 2 of a thickness of berween 0.05mm and 0.5mm which is passed around an accumulator 3 before being guided by rolls 4 into a coaring chamber 5. As rhe srrip 2 enters the chamber 5 it passes through an inducrion hearer ό which hears the srrip ro a remperarure of approximarely 160 C C. Below rhe hearer 6 are posirioned two conrra-rotating rolls 7. The rolls may have a polished or mirrored surface. This finish may be achieved by using chromium or chromium coated rolls. Coils 8 of polypropylene or polyerhylene terephthalate films 9 are positioned within the coating chamber 5. The thickness of the polymer films 9 is preferably between 5 and 100 microns, a typical thickness being 20 microns. Each film is coated on one of its sides with metallic particles to create a reflective surface thereon. Coating is effected by a vapour deposition or a sputtering technique. These particles may be, for example, of aluminium, silver, nickel or stainless steel. Typically the thickness of this coating is lOnm. The other side of the or each film is coated with a bonding layer, the softening or melting point of which is typically between 60° and 230°C and is below the softening or melting point respectively of polypropylene or polyethylene terephthalate or polyvinyl chloride. The films 9 are guided towards the heated strip by a laminator including a series of tensioning and spreading rolls 11 which ensure that the interfaces between the films 9 and the strip are free of creases, stress lines and defects. Bonding of the film layers onto the strip is effected by the rolls 7. The laminated strip 10 then passes via an accumulator 12 to a coiler 14. Some means of forced cooling, e.g. a quenching tank, may be provided within the coating chamber 5. Examples of laminated strip in accordance with the invention are shown in Figures 2 and 3. The laminated strip of Figure 2 comprises a steel substrate 15 of between 0.05 to 0.5mm thickness, a bonding layer 16 of approximarely 2 microns rhickness, a metallised aluminium layer 17 of approximately lOnm thickness and a polyethylene terephthalate layer 18 of between 10 and 100 microns thickness. A clear protective scratch-resistance layer may be applied to the polyethylene terephthalate layer. As tinmill products have a relatively wide range of tensile strengrhs (from 335 ro 660 N/mm 2 ), hardnesses (52 ro 77 HR30T) and elongarions (up to 35%) rhe resulring laminares have unprecedented versatiliry. In addition, because of rhe inrrinsic properries of the steel substrate the laminare is easier ro slir and blank and rool tolerances do not need to be so demanding as wirh aluminium. Because of the exrremely good surface finish that is typical of tinmill producrs (surface roughnesses berter than 0.07 to 0.15 microns centre line average are typical depending on the finish required) it has been found that laminated products of rhis invenrion exhibit particularly good surface finishes. This is surprising because it may be envisaged that the laminated polymer would cover up imperfections in the substrare. However experience has shown that the fine surface finish enhances the specular image produced by the laminated products. The polymer coatings, on especially electrolytically chromium/chromium oxide coarings, have been found ro be particularly advantageous because passivation provides enhanced adhesion and corrosion resisrance. In addition, experiments have confirmed that galvanised strip coated fay the method of the present invention achieves considerable corrosion prorection including cut edge protection. The combina ion of thin gauge and high srrengrh means rhar the application may be owngauged giving little disadvantage ro sreel wirh respecr ro weighr of the finished component when compared wirh aluminium. It is also possible to produce in accordance wirh thiε invention reflecror componenrs from pressings rarher than by bending and folding flat sheets. This has two major advantages; firstly more complex and sophisticated designs can be realised and secondly rhe problem wirh the reflectors not holding rhe exacr shape required by the designer, because of flexing of the relatively flimsy sheers presently used and rhe manual assembly and handling required, are overcome. Thus, significanrly more efficient and effective lumineres can be produced. Current aluminium products require the use of a strippable film to protect polished surfaces during forming and handling. Presently, finished aluminium lumineres are despatched wirh a pair of cotton gloves to aid handling without marking. Once touched marks cannot be removed from the aluminium as the salts on the skin erch it. Polymers are inherenrly more resistant ro marking. In addition, as mentioned previously, it is possible to coat the polymer films with hard scratch resistant layers thereby obviating the necessity for protective films. This would reduce costs of the finished product by up ro 20%. Antistatic coatings may also be used that will reduce the need for cleaning. The laminated strip of Figure 3 has particular applicarion where iridescence is porenrially a problem. Iridescence is the coloured effect exhibited by rhin films or when rhere is defraction. In reflective marerials with thin coatings, iridescence is the effect of interference produced between lighr reflecred from the rop surface of a transparent coating, i.e. a lacquer coating or anodise layer, and the lighr reflecred from rhe surface of a polished substrate. There are particular problems in the lighting industry. Daylight consists of a continuous spectrum of colours that does not produce noticeable iridescence. However many lighr manufacrurers use lamps that produce a limited number of colours to produce the effect of a white or aesthetically tinged white light. Tri-phosphor lamps, for example, are commonly used. These contain a mixture of rare earth phosphors with a light output in rhe red, green and blue wavelengths of the spectrum and when used with anodised aluminium unacceptable rainbow colours are produced. Two merhods that have been used to minimise this effect are to use semi-specular or matt finished materials to scarter the light or to try to build up a rhick anodised layer. Commonly the anodised layer is berween rwo and four microns alrhough in the highest quality materials thicknesses up to five microns may be uεed. The first method suffers from the disadvantage thar the light designer is limited by the diffuse light produced and the second method has the disadvantages that the iridescence is not overcome bur only reduced and the cost for the product is greatly increased. It has been found that reflective laminated strip produced in accordance with the invention has similar reflectance and surface finishes to existing materials but with limited or no iridescence. To achieve this effect, it is necessary to ensure that the transparent layer iε several times thicker than the wavelength of visible light then the interference colours are not then visible. It has been found rhat with a transparent Iayer in excess of about 15 microns (about 25 times the wavelength of visible light) the level of iridescence is reduced to the point where it is barely visible even under the demanding conditions of tri-phosphor bulbs. At 25 microns the iridescent effect is absent. The proposed laminate is shown in Figure 3. The transparent polymer layer 19 is of a thickness of approximately 15 microns and is composed of polyethylene terephthalate, in both crystalline and amorphous forms. In principle, any polymer of adequate transparency and surface finish could be used. The required reflective surface was produced by coating the underside of the polymer layer 19 with a metallic substance 21 ' by vapour deposition or sputtering, for example electron beam sputtering. The thickness of this layer is approximately lOnm. The composite is then bonded to the steel substrate 22 for rigidity using the apparatus described above or by a wet adhesive system. Further layers may be overlaid on the polymer to impart enhanced performance, for example scratch or ultra violet light resistance, but the refractive indices of these materials should be similar to the polymer layer to avoid problems with iridescence. It will be appreciated that the foregoing is merely exemplary of laminated strips, and methods for making such strips, and that modifications can readily be made thereto without departing from the true scope of the invention.

Claims: CLAIMS 1. Corrosion resistant impervious steel strip of a thickness of between 0.05mm to 0.5mm to at least one surface of which is bonded a layer of a polymer. 2. Steel strip as claimed in claim 1 wherein the polymer is polyethylene terephthalate. 3. Steel strip as claimed in claim 1 wherein the polymer is polypropylene. 4. Steel strip as claimed in claim 1 wherein the polymer is polyvinyl chloride. 5. Steel strip as claimed in any one of the preceding claims wherein the thickness of the polymer layer is between 10 and 100 microns. 6. Steel strip as claimed in claim 5 wherein the thickness of the polymer layer is between 10 and 80 microns. 7. Steel strip as claimed in claim 6 wherein the thickness of the polymer layer is between 12 and 50 microns. 8. Steel strips as claimed in claim 6 wherein the thickness of the polymer layer is between 12 and 25 microns. 9. Steel strip as claimed in claim 6 wherein the thickness of the polymer layer is between 15 and 25 microns. 10. Steel strip as claimed in any one of the preceding claims wherein the polymer layer is coated with a film of metallic particles. 11. Steel strip as claimed in claim 10 wherein the thickness of the metallic coating is between 5nm. 12. Steel strip as claimed in claim 11 wherein a bonding promoter is provided between the metallic coating and polymer layer. 13. Steel strip as claimed in any one of the preceding claim 1 wherein the polymer layer includes a bonding layer. 14. Steel strip as claimed in claim 13 wherein the bonding layer takes the form of a coating applied to one surface of the polymer layer or the strip to which the polymer layer is to be applied. 15. Steel strip as claimed in claim 14 wherein the bonding layer has a melting temperature in the range 150°C and 230°C. 16. A method of producing laminated corrosion resistant steel strip of a thickness between 0.05mm and 0.5mm, the method comprising coating black strip of this thickness with a corrosion resistant material by an electrodeposition or galvanising process and subsequently hot roll bonding to one or each surface of the strip a layer of a polymer selected from polyethylene terephthalate or polypropylene or polyvinyl chloride. 17. A method as claimed in claim 16 wherein the steel strip is heated to a temperature of the order of 160°C before it enters the nip of a pair of contra-rotating rolls. 18. A method as claimed in claim 16 or claim 17 wherein the or each polymer layer is guided onto the or each side of the heated strip as it enters the roll nip and is bonded thereto. 19. Corrosion resistant steel strip and a method of providing the same substantially as herein deεcribed with reference to Figures 1 to 3 of the accompanying drawings.

Inventors: BUSBY NICHOLAS JAMES, BUSBY, NICHOLAS, JAMES
Applicants: BRITISH STEEL PLC, BUSBY NICHOLAS JAMES, BUSBY, NICHOLAS, JAMES
Application year: 1996
Main classification: B32B15
IPC codes: B32B15