Patent Description:
Applying a coating on a metal substrate enhance its properties such as corrosion resistance. Polymer coating films are usually laminated on a metal substrate then heated and eventually quenched. This quench, depending on the cooling speed applied, may hinder the formation of crystalline phase within the polymer, that will be partly in an amorphous state. The degree of crystallinity of the coating, which represents the proportion of polymer with a crystalline structure, influences greatly its properties. Thus, it is essential to assess the degree of crystallinity of such coatings to assure that the desired properties, requirements and specifications are met.

In the state of the art, as exemplified by Japanese patent publication <CIT>, the degree of crystallinity of a polymer coating on a metallic substrate is predominantly measured non-destructively using the Raman spectroscopy. This method is negatively impacted by some measurement conditions such as humidity, the chattering of the substrate, the medium between the substrate and the lighting or measuring devices, a variation in the distance between the sample and the measuring or lighting devices. Moreover, the lighting source used during a Raman spectroscopy generally heats the coating and degrades it, favouring the formation of crystalline phase. Furthermore, any light other than the lighting source impacts negatively the measurement precision. Consequently, the measured area needs to be protected from natural and exterior lights which is a major drawback for its industrial use.

Other techniques such as DRX or infrared spectroscopy can measure the degree of crystallinity of polymers but they are not applied on polymer coatings on a metallic substrate.

Besides, using the methods and equipment described in the state of the art, it is only possible to determine the crystallinity degree of a single spot along the substrate coating width. Depending on the technique used, those single spots are more or less spaced in function of the acquisition time, (from at least a dozen of seconds for the Raman spectroscopy to a fraction of second for the infrared spectroscopy) and the substrate speed. <FIG> schematically illustrates the space between two consecutive measured spots depending on the measurement techniques (A: Raman spectroscopy, B and C: infrared spectroscopy, D and E: the present invention), each coloured spot represents a measured spot.

Consequently, there is a need to find a way to measure and represent the degree of crystallinity of a polymer coating, on the full width of such coating deposited on a metallic substrate, without degrading said coating and with a good precision of the measurement.

The purpose of this invention is to meet the aforementioned need.

This object is achieved by providing a method according to claim <NUM>. The method can also comprise any characteristics of claims <NUM> to <NUM>. This object is also achieved by providing an apparatus according to claims <NUM> to <NUM>.

To illustrate the invention, various embodiments will be described, particularly with reference to the following figure:.

The invention relates to a method of mapping the crystallinity of a polymer coating <NUM> on a moving metallic substrate <NUM>, the process repeating the following steps:.

On the figures, only the light beams emitted by the polychromatic light emitter <NUM>, reflected on the moving substrate and measured by the hyperspectral camera are represented. As illustrated in <FIG>, a polymer coating <NUM> deposited on a moving metallic substrate <NUM> is lighted at least in the infrared domain, from <NUM> to <NUM>, with a polychromatic light that can come from a polychromatic light emitter <NUM>. The lighting is done in a way that a transversal zone encompassing the full width W of said polymer coating <NUM> is lighted.

Then a hyperspectral camera <NUM> measures the light intensity Simpacted,λα at a predetermined wavelength λα in the infrared domain, that is impacted by the degree of crystallinity, as explained later. The measurement is done for at least two beams, e.g. B1 and B2, from the polychromatic light emitter <NUM> reflected by said moving metallic substrate <NUM> on at least two locations, e.g. L1 and L2. The locations are defined by the camera.

Then the hyperspectral camera <NUM> measures also the light intensity Sstable,λβ at a predetermined wavelength λβ, in the infrared domain, not impacted by the degree of crystallinity. The measure is done for at least two beams, e.g. B1 and B2, from the polychromatic light emitter <NUM> reflected by said moving metallic substrate <NUM> on at least two locations, e.g. L1 and L2. The locations are defined by the camera.

As illustrated in <FIG>, in the frame of the present invention, a wavelength is affected by the degree of crystallinity when the intensity variation at this wavelength is superior or equal to <NUM>% between a <NUM>% crystalline coating and a <NUM>% amorphous coating. A wavelength is not affected by the degree of crystallinity when the intensity variation at this wavelength is inferior to <NUM>% between a <NUM>% crystalline coating and a <NUM>% amorphous coating.

<FIG> exhibits two spectrums, one of a fully crystalline coating in optimal measurement condition (continuous line), one of a fully amorphous coating in optimal measurement condition (dot + dash). In the frame of the present invention, optimal condition means that the measurement is done on a metallic substrate without any polymer coating on it. Three wavelengths are noted (λ<NUM>, λ<NUM> and λ<NUM>). The wavelength λ<NUM> is considered as unaffected by the degree of crystallinity because its intensity is the same for the fully crystalline coating and for the fully amorphous coating. The wavelength λ<NUM> is also considered as unaffected by the degree of crystallinity as its wavelength intensity difference between the fully crystalline coating and the fully amorphous coating is smaller than <NUM>%. The wavelength λ<NUM> is considered as affected by the degree of crystallinity as the wavelength intensity difference is bigger than <NUM>%.

Then, for each beam, at least an impacted absorbance is determined using said intensity Simpacted,λα at the wavelength λα, impacted by the degree of crystallinity. The higher the intensity variation at a wavelength due to the degree of crystallinity, the more interesting it is to use such a wavelength for determining an impacted absorbance because the measurement will be more precise.

The impacted absorbance can be calculated, for example, using the following equation: <MAT> where:.

In the case where several impacted absorbances are determined for a same location along the coating width, a representative value, Vsimpacted, of them is determined. Preferably, the representative value can be the mean or the median of all the absorbances not impacted by the degree of crystallinity.

Then, for each beam, at least a stable absorbance is determined using said intensity Sstable,λβ at the wavelength λβ not impacted by the degree of crystallinity. The lower the intensity variation at a wavelength due to the degree of crystallinity, the more interesting it is to use such a wavelength for determining an absorbance not impacted by the degree of crystallinity.

The stable absorbance can be calculated, for example, using the following equation: <MAT> where:.

In the case where several stable absorbances are determined for a same location along the coating width, a representative value, Vsstable, of them is determined. Preferably, the representative value can be the mean or the median of all the absorbances not impacted by the degree of crystallinity.

Then, for each beam, a ratio R between the absorbance impacted by the degree of crystallinity and the absorbance not impacted by the degree of crystallinity is determined.

In the case where representative values of the absorbance impacted by the degree of crystallinity and the absorbance not impacted by the degree of crystallinity are determined, the following ratio RV is calculated: <MAT>.

Each ratio R or RV is linked to a degree of crystallinity.

In another embodiment, the impacted absorbance can be, for example, determined using the following equation: <MAT> where:.

In another embodiment, the stable absorbance can be, for example, determined using the following equation <MAT> where:.

<FIG> exhibits two spectrums, one of a fully crystalline coating measured in optimal measurement condition (S1), one of a fully crystalline coating measured in industrial measurement condition (S2) where the measurement conditions are degraded. Due to the different measurement condition, the industrial spectrum can be shifted towards lower or higher value. That is why a ratio of the absorbance calculated above, Aimp2 and Asta2, is preferably used to lower the impact of the measurement condition on the degree of crystallinity.

Then the degree of crystallinity of each beam, or location, is estimated by converting the ratio previously determined into a degree of crystallinity.

Advantageously, as illustrated in <FIG>, said ratio is converted to a degree of crystallinity using abacus. Preferably, the correlation of the abacus between the absorbance and the degree of crystallinity has been confirmed by other measurement method such as DRX, DSC or infrared spectroscopy, beforehand.

A map or a visual representation of the coating degree of crystallinity is made using said previously determined degree of crystallinity and their associated location.

Because all the previously described steps are repeated and the metallic substrate is moving, the degree of crystallinity along the length of the coating polymer can be estimated. The resolution, number of measured spots in a defined area, in the length direction depends on the metallic substrate speed and the acquisition time of the hyperspectral camera. Lower is the speed and lower is the acquisition time, higher will be the resolution.

With the method according to the present invention, the degree of crystallinity of the full width of a polymer coating deposited on a metallic substrate can be measured and represented. Moreover, the degree of crystallinity is not influenced by the operating conditions, such as the chattering of the substrate and humidity, nor is the coating degraded by the lighting source. Furthermore, as illustrated in <FIG>, the resolution of the degree of crystallinity mapping is more precise compared to the state of the art techniques.

Advantageously, said method is repeated regularly so as to cover the full coating surface of said substrate. Preferably, the steps of the method are repeated as often as possible in order to obtain a degree of crystallinity map as precise as it can be.

Advantageously, said polymer coating is made of polyethylene terephthalate (PET).

Advantageously, said metallic substrate is made of steel. Such a substrate improves the measurement quality due to its low rugosity.

Advantageously, λα is comprised between <NUM> and <NUM> micrometres. In an even preferred embodiment, λα is comprised between <NUM> and <NUM> micrometres.

Apparently, some waves in those ranges are more impacted by the degree of crystallinity than in other ranges. Consequently, measuring the intensity of rays having such wavelengths enables a better estimation of the polymers degree of crystallinity.

Advantageously, said at least one hyperspectral camera measures the intensity of at least a wavelength comprised between <NUM> and <NUM> micrometres having its wavelength intensity not impacted by the degree of crystallinity. Using this range enables to have one of the most unaffected intensity by the crystallinity degree. In other words, the variation intensity in function of the crystallinity degree is almost inexistent which permits to establish a good reference independently of the measurement condition.

Advantageously, the step b) is done on at least <NUM> locations within said transversal area. Doing the measures on at least <NUM> locations along the coating width increases the resolution of the crystallinity degree map. Thus, the probability to detect a default, where the crystallinity is different than the desired one is higher.

The invention also relates to an equipment <NUM> for online measurement of crystallinity degree of polymer coatings on a metallic substrate, comprising,.

As illustrated in <FIG>, a polymer layer deposited on a substrate is conveyed, by conveying means such as rolls <NUM>. The measurement equipment, composed of at least a lighting source <NUM> and at least one hyperspectral camera <NUM>, is positioned above said polymer layer deposited on a substrate and means to convey said substrate (not represented). Said hyperspectral camera can record a spectrum of wavelength intensity for each pixel and is oriented in order to record the beams reflected on the polymer layer deposited on a substrate from the lighting source.

Advantageously, said hyperspectral camera <NUM> is oriented to make an angle comprised between <NUM>° and <NUM>°, preferentially between <NUM>° and <NUM>° and more preferably <NUM>° with the metallic substrate. On one hand, as illustrated in <FIG> by the <NUM>° beam, smaller is the measurement angle, shorter is the distance passed by the beam through the coating and thus smaller is the intensity variation detected. On the other hand, as illustrated in <FIG> by the <NUM>° beam, higher is the measurement angle, longer it the distance passed by the beam through the coating and thus more sensible is the intensity variation detected to the substrate vibrations. Consequently, closer is the angle to <NUM>°, better is the compromise between a sufficient intensity variation and a small vibration perturbation.

Advantageously, said polychromatic light emitter <NUM> is an infrared lighting source. Contrary to a LASER, an infrared lighting source is less prone to damage the coating because the power used is generally about <NUM><NUM> to <NUM><NUM> times lower than for the LASER lighting sources.

Advantageously, said polychromatic light emitter <NUM> is a made of at least a metal or ceramic. Preferentially, the lighting source is a heated nickel chrome rod or a heated ceramic plate heated. Such a heating enables a higher emission of light in the infrared domain in which there are absorbance affected and unaffected by the degree of crystallinity. Depending on the heating temperature, the intensity of the emitted wavelengths varies. Preferably, said bar or ceramic are heated between <NUM> and <NUM>.

Advantageously, as illustrated in <FIG>, said equipment comprises a convex reflection mean <NUM> being positioned to reflect the light from the polychromatic light emitter <NUM> onto said substrate, said convex reflection mean <NUM> and the hyperspectral camera <NUM> being set-up in specular reflection towards said substrate. Such a device permits to concentrate the lighting intensity on an area, thus enabling a better and more precise measurement.

Claim 1:
A method of mapping the crystallinity degree of a polymer coating (<NUM>) of a moving metallic substrate (<NUM>), the process comprising the following steps:
a) lighting a transversal area of said of said polymer coating (<NUM>) encompassing its full width W, with a polychromatic light including wavelengths in the infrared domain,
b) measuring with at least one hyperspectral camera (<NUM>),
- the light intensity Simpacted,λα at a predetermined wavelength λα impacted by the degree of crystallinity of said coating in the infrared domain and
- the light intensity Sstable,λβ at a predetermined wavelength λβ not impacted by the degree of crystallinity of said coating in the infrared domain of at least two light beams (B1, B2) from said polychromatic light after reflection on said moving metallic substrate (<NUM>) on two different locations (L1, L2) within said transversal area,
c) determining at least an impacted absorbance Aimp, using said light intensity Simpacted,λα at said predetermined wavelength λα impacted by the degree of crystallinity for each beam (B1, B2),
d) determining at least a stable absorbance Asta, using said light intensity Sstable,λβ at said predetermined wavelength λβ not impacted by the degree of crystallinity for each beam (B1, B2),
e) determining, for each beam (B1, B2), a ratio, R, equals to Aimp/Asta
f) converting each ratio R to a degree of crystallinity,
g) mapping the degree of crystallinity of said polymer coating in said transversal area using said degree of crystallinity and said locations (L1, L2).